Modular, flexible, automated frame welding fixture system and control method

Abstract

The application provides a modular, flexible and automatic frame welding clamp system and a control method, which comprises a pressing module, a positioning module, a quick gas path connecting module, a welding platform module and a control system. According to the process characteristics of the frame structure, a clamping scheme is designed, the frame placement position, the pressing position and the positioning position are determined, then the pressing module and the positioning module are installed at the corresponding positions of the welding platform, the quick gas path is connected, the frame parts are placed, and finally the automatic clamping and fixing of the frame are realized through the control system. The control system is composed of a PLC, a touch screen and a cable. The pressing module, the positioning module and the quick gas path connecting module realize flexible installation of different numbers and different positions on the welding platform module according to the process characteristics of the frame structure, and realize automatic clamping and fixing through the control system.

Description

Technical Field

[0001] This invention relates to the fields of modular shelters, frame welding, and pneumatic clamps, and particularly to modular, flexible, and automated frame welding clamp systems and control methods. Background Technology

[0002] The modular cabin frame is typically constructed using profile welding, meaning it's assembled from multiple profiles. This method is characterized by large dimensions, high precision, small batch production, and diverse product range. Previously, frame welding employed either manual or custom-tooled methods. The manual method involved measuring dimensions, manually assembling the frame structure, clamping it with manual fixtures, and finally welding. This method suffers from several drawbacks, including errors in dimensional measurement, poor frame flatness, inadequate clamping affecting welding quality, and low production efficiency. The custom-tooled method involved selecting custom fixtures based on the frame drawings, hoisting them (if other custom fixtures were present on the welding platform, they needed to be removed first), assembling the frame, pneumatically clamping it, and finally welding. However, this method is disadvantageous due to difficulties in disassembling the fixtures and the high cost of custom fixture construction, making it unsuitable for small-batch, multi-product operations.

[0003] In the process of welding the large plate frame of the modular hospital, how to solve the problems of product quality, production efficiency and capital investment in the manual operation mode or the customized tooling operation mode, which are characterized by large size, high precision, small batch and multiple varieties, and achieve flexible, automated and modular frame welding, is one of the problems that those skilled in the art have always hoped to solve. Summary of the Invention

[0004] Objective of the Invention: The technical problem to be solved by this invention is to address the shortcomings of existing technologies by providing a modular, flexible, and automated frame welding fixture system. Based on the characteristics of the frame, the placement, clamping, and positioning positions of the frame are determined. Then, clamping and positioning modules are installed at the corresponding positions on the welding platform, and a rapid air circuit is connected for frame placement. Finally, the frame is quickly clamped through a control system.

[0005] The system of this invention includes a clamping module, a positioning module, a rapid air circuit connection module, a welding platform module, and a control system. The clamping scheme is designed according to the characteristics of different frame structures, and the clamping module and positioning module are flexibly installed. Then, the rapid air circuit connection module is connected, and finally, the control system realizes automated clamping and fixing.

[0006] The clamping module includes a first mounting base, a rotary clamping cylinder, and a clamping head;

[0007] The first mounting base has a flat plate structure, including a fixing area, an installation area, and a support area. The fixing area has pre-drilled racetrack-shaped holes for connection with the welding platform. The installation area has four countersunk holes pre-drilled on the back after being sunk to a certain thickness (generally 5mm to 15mm) for fixing with a rotary clamping cylinder. The support area has a planar structure, and its size is adjusted according to the specifications of the frame profile for supporting the profile.

[0008] The rotary clamping cylinder is a 90° angle cylinder;

[0009] The pressure head adopts a figure-7 shaped assembly structure, including a crossbar and a longitudinal bar. The crossbar is in the form of a flat plate, with a pre-drilled round hole at one end for connection with the rotary clamping cylinder, and a pre-drilled threaded hole at the other end for connection with the longitudinal bar. The longitudinal bar is in the form of a cylinder, with a threaded end for connection with the threaded hole on the crossbar, and the other end contacts the workpiece to perform a clamping function.

[0010] The positioning module includes a second mounting base, a dual-axis dual-rod cylinder, and a reference base;

[0011] The second mounting base has a flat plate structure with pre-drilled racetrack-shaped holes on both sides for connection to the welding platform, and four countersunk holes on the back of the middle area for connection to the dual-axis dual-rod cylinder.

[0012] The dual-shaft dual-rod cylinder is a high-thrust type dual-shaft dual-rod cylinder.

[0013] The reference base adopts an L-shaped integral structure with a pre-drilled racetrack-shaped hole at the bottom for connection with the welding platform.

[0014] The welding platform module includes a welding platform and pneumatic piping;

[0015] The welding platform is designed as a porous gray cast iron welding platform, and the platform surface is also designed with an array of circular holes as air passage interfaces.

[0016] The pneumatic pipeline is arranged at the bottom of the welding platform and includes a main pipeline, branch pipelines, terminal pipelines and solenoid valves; wherein the main pipeline is a steel round pipe, one end is connected to the air source and the other end is sealed, and the side of the main pipeline has a reserved interface for connection with the branch pipeline.

[0017] The branch pipeline adopts a standard threaded gas distributor and is equipped with a solenoid valve installation interface;

[0018] The solenoid valve is a 24V industrial type solenoid valve;

[0019] The terminal pipeline is made of steel round pipe, with one end connected to the solenoid valve and the other end being a quick connector installed at the gas line interface of the welding platform.

[0020] The rapid gas path connection module includes a first rapid connection unit and a second rapid connection unit;

[0021] The first quick-connect unit is used to connect the rotary clamping cylinder, the dual-axis dual-rod cylinder, and the air circuit interface of the welding platform module;

[0022] The second quick-connect unit is used to connect the main pipeline of the welding platform module to the gas source;

[0023] The first quick-connect unit and the second quick-connect unit are respectively composed of air tubes and quick connectors of different lengths (generally 100mm to 1000mm).

[0024] The control system includes a programmable logic controller (PLC), a touch screen, and cables; wherein the touch screen is connected to the PLC via cables, and the solenoid valve is connected to the I / O interface on the PLC.

[0025] The clamping module, positioning module, and quick air circuit connection module can be quickly installed on the welding platform in different quantities and positions according to the structural characteristics of the frame. The clamping module and positioning module are connected to the welding platform through the first mounting base and the second mounting base, respectively, and the connection method is quick locking pin locking. The quick air circuit connection module is connected to the rotary clamping cylinder and the dual-shaft dual-rod cylinder.

[0026] Furthermore, the present invention also provides a control method for a modular, flexible, and automated frame welding fixture system, comprising the following steps:

[0027] Step 1: Determine if the current frame drawing is stored. If so, directly call the stored clamping scheme and jump to step 4; otherwise, jump to step 2.

[0028] Step 2: On the frame diagram to be clamped displayed on the touch screen, divide the frame into n independent group control clamping areas, where n is generally 1 to 10.

[0029] Step 3: Set the automatic clamping start sequence for each group control clamping area in turn;

[0030] Step 4: Connect the solenoid valve to the programmable logic controller (PLC) according to the set automatic clamping start sequence of the group control clamping area;

[0031] Step 5: The programmable logic controller (PLC) determines whether the solenoid valve is connected. If it is, proceed to step 6; otherwise, proceed to step 4.

[0032] Step 6: The clamps begin to automatically clamp the frames one by one according to the designated areas;

[0033] Step 7: Determine if the number of clamped areas is equal to n. If yes, proceed to step 8; otherwise, proceed to step 6.

[0034] Step 8: Display the clamping complete and save the current clamping scheme.

[0035] The present invention has the following beneficial effects: This modular, flexible and automated frame welding fixture system has a simple structure and features modularity, flexibility and automation. It can solve the problems of product quality, production efficiency and capital investment that exist in manual operation mode or customized tooling operation mode. Attached Figure Description

[0036] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments, and the advantages of the present invention in the above and / or other aspects will become clearer.

[0037] Figure 1 This is a flowchart of the implementation method of the system of the present invention.

[0038] Figure 2 This is a schematic diagram of the system of the present invention.

[0039] Figure 3 This is a schematic diagram of the clamping module.

[0040] Figure 4 This is a schematic diagram of the positioning module.

[0041] Figure 5 This is a schematic diagram of the quick air circuit connection module.

[0042] Figure 6 This is a schematic diagram of the welding platform module.

[0043] Figure 7 This is a flowchart of the control system's workflow. Detailed Implementation

[0044] The system of the present invention includes a pressing module 7, a positioning module 8, a rapid air circuit connection module 9, a welding platform module 10, and a control system.

[0045] In this invention, the clamping module 7 includes a first mounting base 1, a rotary clamping cylinder 3, and a pressure head 4. The first mounting base 1 is made of steel plate, with a flat structure, and is divided into a fixing area, an installation area, and a support area. The fixing area has pre-drilled racetrack-shaped holes for connection to the welding platform; the installation area has four countersunk holes on its back after being recessed to a certain thickness for fixing the rotary clamping cylinder 3; the support area is a planar structure, with dimensions adjusted according to the profile specifications of the frame 11, for supporting the profile; the rotary clamping cylinder 3 is a 90° angle cylinder; the pressure head 4 adopts a "7"-shaped assembly structure, divided into a crossbar and a longitudinal bar. The crossbar is flat, with a pre-drilled round hole at one end for connection to the rotary clamping cylinder 3, and a pre-drilled threaded hole at the other end for connection to the longitudinal bar. The longitudinal bar is cylindrical, with a threaded end for connection to the threaded hole on the crossbar.

[0046] In this invention, the positioning module 8 includes a second mounting base 2, a dual-axis dual-rod cylinder 5, and a reference base 6. The second mounting base 2 is made of steel plate, with a flat plate structure. Raceway-shaped holes are pre-drilled on both sides for connection to the welding platform, and four countersunk holes are pre-drilled on the back of the middle area for connection to the dual-axis dual-rod cylinder 5. The dual-axis dual-rod cylinder 5 is a high-thrust type. The reference base 6 adopts an "L"-shaped integral structure with raceway-shaped holes pre-drilled at the bottom for connection to the welding platform.

[0047] In this invention, the quick air connection module 9 includes a first quick connection unit and a second quick connection unit. The first quick connection unit is used to connect the cylinder to the air interface 12 of the welding platform module 10, and the second quick connection unit is used to connect the main air supply of the welding platform module 10 to the air source 13. The first quick connection unit and the second quick connection unit are respectively composed of air pipes of different lengths and quick connectors.

[0048] In this invention, the welding platform module 10 includes a welding platform and pneumatic piping. The welding platform is designed as a porous gray cast iron welding platform, and the platform surface is also designed with an array of circular holes as pneumatic inlets 12. The pneumatic piping is arranged at the bottom of the welding platform and includes a main pipe 14, branch pipes 15, end pipes 16, and a solenoid valve 17. The main pipe 14 is made of steel round pipe, with one end connected to the air source 13 and the other end sealed. The side of the main pipe 14 has a reserved interface for connecting to the branch pipes 15; the branch pipes 15 are standard threaded air distributors and are equipped with a solenoid valve 17 mounting interface; the solenoid valve 17 is a 24V industrial solenoid valve; the end pipe 16 is made of steel round pipe, with one end connected to the solenoid valve 17 and the other end being a quick connector, installed at the pneumatic inlet 12 of the welding platform.

[0049] In this invention, the control system includes a PLC, a touch screen, and cables. The touch screen is connected to the PLC, and the solenoid valve 17 is connected to the I / O interface of the PLC.

[0050] In this invention, the clamping module 7, positioning module 8, and rapid air circuit can be rapidly installed on the welding platform in different quantities and positions according to the structural characteristics of the frame 11, and the frame 11 can be automatically and rapidly clamped through the control system. Specifically, the clamping module 7 and positioning module 8 are connected to the welding platform via the first mounting base 1 and the second mounting base 2, respectively, using a rapid locking pin connection; the rapid air circuit is connected to the rotary clamping cylinder 3 and the dual-axis dual-rod cylinder 5, respectively.

[0051] Example

[0052] like Figure 1 As shown, the present invention provides a modular, flexible, and automated frame welding fixture system and control method. The system is implemented by determining the placement position, clamping position, and positioning position of the frame 11 based on its characteristics, then installing the clamping module 7 and positioning module 8 at the corresponding positions on the welding platform, connecting the rapid air circuit, placing the frame 11, and finally realizing the rapid clamping of the frame 11 through the control system.

[0053] like Figure 2 As shown, the system includes a clamping module 7, a positioning module 8, a rapid air circuit connection module 9, a welding platform module 10, and a control system.

[0054] like Figure 3 As shown, the clamping module 7 includes a first mounting base 1, a rotary clamping cylinder 3, and a pressure head 4. The first mounting base 1 is made of steel plate, with a flat structure, and is divided into a fixing area, an installation area, and a support area. The fixing area has pre-drilled racetrack-shaped holes for connection to the welding platform; the installation area has four countersunk holes on its back after being recessed to a certain thickness for fixing the rotary clamping cylinder 3; the support area is a planar structure, with dimensions adjusted according to the profile specifications of the frame 11, for supporting the profile; the rotary clamping cylinder 3 is a 90° angle cylinder; the pressure head 4 adopts a "7"-shaped assembly structure, divided into a crossbar and a longitudinal bar. The crossbar is flat, with a pre-drilled round hole at one end for connection to the rotary clamping cylinder 3, and a pre-drilled threaded hole at the other end for connection to the longitudinal bar. The longitudinal bar is cylindrical, with a threaded end for connection to the threaded hole on the crossbar.

[0055] like Figure 4 As shown, the positioning module 8 includes a second mounting base 2, a dual-axis dual-rod cylinder 5, and a reference base 6. The second mounting base 2 is made of steel plate, with a flat plate structure. Raceway-shaped holes are pre-drilled on both sides for connection to the welding platform, and four countersunk holes are pre-drilled on the back of the middle area for connection to the dual-axis dual-rod cylinder 5. The dual-axis dual-rod cylinder 5 is a high-thrust type. The reference base 6 adopts an "L"-shaped integral structure with raceway-shaped holes pre-drilled at the bottom for connection to the welding platform.

[0056] like Figure 5As shown, the quick-connect pneumatic circuit module 9 includes a first quick-connect unit and a second quick-connect unit. The first quick-connect unit is used to connect the cylinder to the pneumatic circuit interface 12 of the welding platform module 10, and the second quick-connect unit is used to connect the main pipeline 14 of the welding platform module 10 to the pneumatic source 13. The first quick-connect unit and the second quick-connect unit are respectively composed of pneumatic pipes of different lengths and quick connectors.

[0057] like Figure 6 As shown, the welding platform module 10 includes a welding platform and pneumatic piping. The welding platform is designed as a porous gray cast iron welding platform, and the platform surface is also designed with an array of circular holes as air inlets 12. The pneumatic piping is arranged at the bottom of the welding platform and includes a main pipe 14, branch pipes 15, end pipes 16, and a solenoid valve 17. The main pipe 14 is made of steel round pipe, with one end connected to the air source 13 and the other end sealed. The side of the main pipe 14 has a reserved interface for connecting to the branch pipes 15; the branch pipes 15 are standard threaded air manifolds and are equipped with a solenoid valve 17 mounting interface; the solenoid valve 17 is a 24V industrial type solenoid valve; the end pipe 16 is made of steel round pipe, with one end connected to the solenoid valve 17 and the other end being a quick connector, installed at the air inlet 12 of the welding platform. Figure 6 In the diagram, 18 is the quick air circuit installation interface, and 19 is the installation interface for positioning module 8 and clamping module 7.

[0058] The control system consists of a PLC, a touch screen, and cables. The touch screen is connected to the PLC, and the solenoid valve 17 is connected to the I / O interface on the PLC.

[0059] like Figure 1 As shown, the clamping module 7, positioning module 8, and rapid air circuit can be quickly installed on the welding platform in different quantities and positions according to the structural characteristics of the frame 11, and the frame 11 can be automatically and quickly clamped through the control system. The clamping module 7 and positioning module 8 are connected to the welding platform through the first mounting base 1 and the second mounting base 2, respectively, and are locked by quick-locking pins. The rapid air circuit is connected to the rotary clamping cylinder and the dual-shaft dual-rod cylinder, respectively.

[0060] like Figure 7 As shown, the present invention also provides a control method for the system, characterized by comprising the following steps:

[0061] Step 1: Determine if the current frame drawing has been saved. If so, directly call the saved clamping scheme and jump to step 4; otherwise, jump to step 2.

[0062] Step 2: On the frame diagram to be clamped displayed on the touch screen, divide the frame into n independent group control clamping areas;

[0063] Step 3: Set the automatic clamping start sequence for each group control clamping area in turn;

[0064] Step 4: Connect solenoid valve 17 to PLC according to the set group of holes area and start-up sequence;

[0065] Step 5: The PLC determines whether the connected solenoid valve 17 matches the setting. If it does, it jumps to step 6; otherwise, it jumps to step 4.

[0066] Step 6: Click the Start Automatic Clamping button. The clamp will automatically clamp the frame one by one according to the designated area.

[0067] Step 7: Based on the positioning signal transmitted by solenoid valve 17, determine whether the current area has been clamped in place. If so, proceed to step 9; otherwise, pause the current step, pop up an alarm prompt, and proceed to step 8.

[0068] Step 8: Manually adjust the frame placement and the position of the group control fixture, then click the "Continue Clamping" button on the touch screen to proceed to Step 7;

[0069] Step 9: Determine if the number of currently clamped areas is equal to n. If yes, proceed to step 10; otherwise, proceed to step 6.

[0070] Step 10: Display that clamping is complete, and store the current clamping scheme according to the frame drawing number. Clamping is finished.

[0071] This invention provides a modular, flexible, and automated frame welding fixture system and control method. Many methods and approaches exist for implementing this technical solution; the above description is merely a preferred embodiment of the invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications should also be considered within the scope of protection of this invention. All components not explicitly stated in this embodiment can be implemented using existing technologies.

Claims

1. A modular, flexible, and automated frame welding fixture system, characterized in that, It includes a clamping module (7), a positioning module (8), a quick air circuit connection module (9), a welding platform module (10), and a control system; the clamping scheme is designed according to the characteristics of different frame structures, the clamping module (7) and the positioning module (8) are flexibly installed, then the quick air circuit connection module (9) is connected, and finally the automatic clamping and fixing is achieved through the control system; The clamping module (7) includes a first mounting base (1), a rotary clamping cylinder (3), and a pressure head (4); The first mounting base (1) is a flat plate structure, including a fixing area, an installation area and a support area. The fixing area has a pre-drilled racetrack-shaped hole for connecting with the welding platform. The installation area has four pre-drilled holes on the back after being sunk to a certain thickness for fixing with a rotating clamping cylinder (3). The support area is a planar structure, and its size is adjusted according to the frame profile specifications for supporting the profile. The rotary clamping cylinder (3) is a 90° angle cylinder; The pressure head (4) adopts a 7-shaped assembly structure, including a horizontal bar and a vertical bar. The horizontal bar is in the form of a flat plate, with a pre-drilled round hole at one end for connecting with the rotary pressing cylinder (3), and a pre-drilled threaded hole at the other end for connecting with the vertical bar. The vertical bar is in the form of a cylinder, with a threaded end for connecting with the threaded hole on the horizontal bar, and the other end contacts the workpiece to play a pressing role. The positioning module (8) includes a second mounting base (2), a dual-axis dual-rod cylinder (5), and a reference base (6); The second mounting base (2) is a flat plate structure with pre-drilled racetrack-shaped holes on both sides for connecting to the welding platform, and four countersunk holes on the back of the middle area for connecting to the dual-axis dual-rod cylinder (5). The dual-shaft dual-rod cylinder (5) is a high-thrust dual-shaft dual-rod cylinder; The reference base (6) adopts an L-shaped integral structure with a pre-drilled runway-shaped hole at the bottom for connection with the welding platform; The welding platform module (10) includes a welding platform and pneumatic pipelines; The welding platform is designed as a porous gray cast iron welding platform, and the welding platform surface is also designed with an array of circular holes as gas passage interfaces (12). The pneumatic pipeline is arranged at the bottom of the welding platform and includes a main pipeline (14), a branch pipeline (15), an end pipeline (16) and a solenoid valve (17); wherein the main pipeline (14) is made of steel round pipe, one end is connected to the air source (13), and the other end is sealed. An interface is reserved on the side of the main pipeline (14) for connecting with the branch pipeline (15). The branch pipe (15) adopts a standard threaded gas distributor and is equipped with a solenoid valve (17) installation interface; The solenoid valve (17) is a 24V industrial type solenoid valve; The terminal pipe (16) is made of steel round pipe, one end of which is connected to the solenoid valve (17), and the other end is a quick connector, which is installed at the gas interface (12) of the welding platform. The rapid gas path connection module (9) includes a first rapid connection unit and a second rapid connection unit; The first quick connection unit is used to connect the rotary clamping cylinder (3), the dual-axis dual-rod cylinder (5) to the air circuit interface (12) of the welding platform module (10); The second quick connection unit is used to connect the main pipeline (14) of the welding platform module (10) to the gas source (13); The first quick-connect unit and the second quick-connect unit are respectively composed of air tubes and quick connectors of different lengths; The control system includes a programmable logic controller (PLC), a touch screen, and cables; wherein the touch screen is connected to the PLC via cables, and the solenoid valve (17) is connected to the I / O interface on the PLC. The clamping module (7), positioning module (8), and quick air circuit connection module (9) can be quickly installed on the welding platform in different quantities and positions according to the structural characteristics of the frame. The clamping module (7) and positioning module (8) are connected to the welding platform through the first mounting base (1) and the second mounting base (2) respectively, and the connection method is quick locking pin locking. The quick air circuit connection module (9) is connected to the rotary clamping cylinder (3) and the double-shaft double-rod cylinder (5) respectively. The control method of the system includes the following steps: Step 1: Determine if the current frame drawing is stored. If so, directly call the stored clamping scheme and jump to step 4; otherwise, jump to step 2. Step 2: On the frame diagram to be clamped displayed on the touch screen, divide the frame into n independent group control clamping areas; Step 3: Set the automatic clamping start sequence for each group control clamping area in turn; Step 4: Connect the solenoid valve (17) to the programmable logic controller (PLC) according to the set automatic clamping start sequence of the group control clamping area; Step 5: The programmable logic controller (PLC) determines whether the solenoid valve (17) is connected. If it is, it jumps to step 6; otherwise, it jumps to step 4. Step 6: The clamps begin to automatically clamp the frames one by one according to the designated areas; Step 7: Determine if the number of clamped areas is equal to n. If yes, proceed to step 8; otherwise, proceed to step 6. Step 8: Display the clamping complete and save the current clamping scheme.

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