A flexible intelligent spot welding station

Abstract

The present application relates to a kind of flexible intelligent spot welding station, including flexible rotary table, spot welding robot system, touch screen system, central control system, welding mechanism and light-weight sealed water cooling system, each component is set on frame body, tooling clamp is set on flexible rotary table along the guide plate of flexible rotary table, part product is set on tooling clamp, spot welding robot system drives welding mechanism to execute resistance spot welding, matching instruction is sent to central control system by touch screen system to carry out unified scheduling, light-weight sealed water cooling system allocates welding mechanism to execute corresponding instruction, to ensure that temperature is always between equipment stable operation value during welding process.Adopting the device disclosed in the present application, the integration is high, full-process automatic control, without manual and specific machine leading, avoid the occurrence of product quality consistency difference, personal injury safety risk, improve production efficiency, improve the intelligent level of light-weighted body-in-white manufacturing industry.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of vehicle welding, and particularly relates to a flexible intelligent spot welding station. BACKGROUND

[0002] At present, the connection mode between lightweight body-in-white parts is mainly resistance spot welding, and the high temperature generated in the welding process is mainly cooled by water medium circulation. The lightweight body-in-white parts are various in types and different in structural forms, and the equipment compatibility is poor. The welding of specific body-in-white parts is completed by manual work and specific machine combination into a fixed unit island. In addition, the pipe splicing technology of the water cooling system is the thread connection process of the car forming.

[0003] Since the body-in-white parts are all thin-walled sheet metal parts, the parts are various in types, different in shapes, and large in size. The main material used by the water cooling system is thick-walled galvanized steel pipe, and the pipe splicing process is the thread connection process of the car forming. At present, the water cooling system composed of manual work, thick-walled galvanized steel pipe and thread connection process undertakes the cooling function and performs the resistance spot welding process of the body-in-white parts, so as to realize the welding of the body-in-white parts.

[0004] The current body welding and cooling process has the following technical defects: ① It cannot be linked, the waiting time is long, and the production efficiency is low. ② The turntable workbench is not flexible, occupies a large area of production site, reduces the utilization rate of production area, and also makes the on-site management difficult. ③ The equipment is low in intelligence, cannot replace the product flexibly according to the demand, has high labor intensity, and long-term low-efficiency and irregular production rhythm causes great harm to the operators. ④ The working condition is not safe, and there is a risk of injury. ⑤ It is limited by the shortage of workers, and there is a defect of stopping the normal operation of the production line. ⑥ It depends on the operation proficiency of personnel, and the product quality consistency is poor, so the product quality cannot be guaranteed. ⑦ The amount of steel is large, and the manufacturing cost is high; ⑧ The amount of steel consumption is large, and the cost is large; ⑨ The thread is not sealed and self-locked, and the pipe leaks water, which endangers the safe operation of the equipment.

[0005] Therefore, an intelligent and automatic welding device is needed in the prior art to realize the automatic welding of different product parts. SUMMARY

[0006] In view of the defects in the prior art, the purpose of the present application is to provide a flexible intelligent spot welding station, which has the technical advantages of linkage cooperation flexibility and small area occupation, can realize automatic control of the whole process of detection, spot welding, and material replacement, does not need manual work and specific machine guidance, avoids the occurrence of poor product quality consistency and personal injury safety risk, improves the production efficiency, and improves the intelligent level of the lightweight body-in-white manufacturing industry. At the same time, the green connection process is adopted to improve the safety and stability of the equipment.

[0007] To achieve the above object, the technical scheme adopted by the present application is: a flexible intelligent spot welding station, the spot welding station comprises a frame body, a flexible turntable, a spot welding robot system, a touch screen system, a central control system, a welding mechanism, a compressed air unit, a safety protection system, a lightweight sealed water cooling system, an electrode cap grinding and detection device, and an electrode cap automatic feeding and discharging device, each component is arranged on the frame body, two groups of the electrode cap grinding and detection device and the electrode cap automatic feeding and discharging device are symmetrically distributed on both sides of the spot welding robot system, two groups of the welding mechanism are arranged on the spot welding robot system, and the electrode cap grinding and detection device and the electrode cap automatic feeding and discharging device are arranged between the spot welding robot system and the flexible turntable.

[0008] The tool clamp is positioned and clamped on the flexible turntable along the guide plate of the flexible turntable, the part product is positioned and clamped on the tool clamp, the spot welding robot system drives the welding mechanism to perform resistance spot welding, after the spot welding of the part product of the type is completed, other types of part products and tool clamps can be replaced, the flexible turntable is flexibly adjusted through the change of the double workbench surface stop and the pneumatic, so as to fix clamps of different sizes, the touch screen system sends matching instructions to the central control system for unified scheduling, and the lightweight sealed water cooling system adjusts the welding mechanism to execute corresponding instructions, so as to ensure that the temperature in the welding process is always between the stable operation values of the equipment.

[0009] The electrode cap grinding and detection device is used for detecting the attachments on the surfaces of the two electrode caps of the moving and static arms of the welding mechanism, the wear state and the correction of the two electrode caps to the concentricity, when the detection evaluation result is that the wear of the surface of the electrode cap exceeds the grinding range value, the central control system sends an electrode replacement instruction, the spot welding robot system moves the welding mechanism to the electrode cap automatic feeding and discharging device after receiving the instruction, and performs the electrode cap process action, the waste gas generated in the spot welding process is all collected, stored, filtered and discharged, and the safety protection system is used for production safety protection.

[0010] Further, the frame body is divided into upper and lower two layers, the lower layer is a functional area for providing installation space for each component, and the upper layer is a data scheduling center area, the frame body comprises two bases, the two bases are oppositely arranged, a plurality of equal-height foot supports are extended upward from the two bases, a top platform is arranged at the top of the foot supports, the height of the frame body is adjusted by adjusting the height of the foot supports, the height of the frame body is adapted to the connection equipment, the frame body is fixed by bolts, a plurality of mounting plates are arranged on the bases, and mounting grooves are arranged around the mounting plates, so as to fix and install each component.

[0011] Further, the flexible rotary table is a split structure, and comprises a first stand, a second stand, a workbench, a guide plate, a universal ball, a limiting block, a stop block, a cylindrical pin, a cylinder assembly, a cylinder support, a connecting rod, a junction box, a servo motor, a speed reducer and a bearing, and is composed of two independent components of a driving end and a driven end to form an open chain mechanism, the two components are respectively based on the first stand and the second stand as a main structure, and are concentrically arranged with the workbench rotation center line as a reference, and the two components are connected into a closed chain mechanism through a tool clamp.

[0012] The inclined edge of the guide plate is used for ensuring quick positioning of the tool clamp, the straight edge of the guide plate is used for ensuring quick positioning of the tool clamp, the spherical support of the universal ball is used for supporting the bottom surface of the tool clamp bottom plate to reduce the change resistance, the limiting block is used for safely limiting the tool clamp, the stop block guide hole is used for ensuring the operation accuracy of the cylindrical pin extension and retraction, and the cylindrical pin is used for ensuring quick positioning of the tool clamp, and the cylindrical pin stop edge is used for centering the tool clamp and the part product.

[0013] The cylinder assembly, the cylinder support, the connecting rod, the cylindrical pin and the compressed air unit form a parallel combined mechanism, the compressed air unit drives the two-end cylindrical pins to synchronously and concentrically extend and retract, thereby ensuring the centering accuracy of the tool clamp and the part product.

[0014] The junction box is used for modular quick insertion, the servo motor, the speed reducer, the workbench of the driving end, the tool clamp, the workbench of the driven end and the bearing form a series combined mechanism, the servo motor and the speed reducer provide a driving source to drive the workbench of the driving end to rotate, and drive the tool clamp and the workbench of the driven end to synchronously move.

[0015] Further, two point welding robot systems are distributed on both sides of the point welding station and are independently controlled by a first welding signal processor and a second welding signal processor, the point welding robot system comprises a point welding robot and a point welding robot base, and the point welding robot base is fixed on a point welding robot base mounting plate in the frame body.

[0016] Further, the spot welding station comprises two welding mechanisms, the welding mechanisms comprising a movable arm welding tong, a static arm welding tong, a servo motor and a transformer, the welding mechanisms being located at the end of the spot welding robot, the movable arm welding tong and the static arm welding tong being designed in pairs, the servo motor receiving instructions from the central control system and outputting the received instructions to the movable arm welding tong and the static arm welding tong in real time to drive corresponding mechanical movements, and accordingly controlling the electrode caps of the movable arm welding tong and the static arm welding tong to realize welding heat connection and blocking welding; the transformer reduces the input voltage and increases the output current to generate sufficient heat for resistance welding; the inner cavities of the movable arm welding tong and the static arm welding tong form a circulating cooling water path.

[0017] Further, the compressed air units are respectively arranged at corresponding positions of the flexible turntable, the electrode cap grinding and detection device and the electrode cap automatic feeding and discharging device, and are uniformly allocated and independently controlled by the central control system.

[0018] Further, the lightweight sealed water cooling system comprises a steel pipe, a steel pipe joint, a stainless steel ball valve, a filter valve, a water flow sensor, a water cut-off valve, a water return cylinder, two electrically controlled electromagnetic valves, a pressure switch, a slow pneumatic valve, an air source three-way joint and a compressed air unit. The cooling liquid flows from a water inlet, passes through the stainless steel ball valve and the filter valve, and is then divided into two water paths. One water path leads to the welding mechanism and then to a water outlet. The other water path leads to the water cut-off valve, is then divided into two water paths, one of which leads to the transformer and then to the water cut-off valve, the water flow sensor and the stainless steel ball valve, and then to the water outlet. The other water path leads to the movable arm welding tong and the static arm welding tong, and then to the pressure switch. One of the two water paths leads to the water return cylinder, and the other water path leads to the water cut-off valve, the water flow sensor and the stainless steel ball valve, and then to the water outlet.

[0019] Further, the electrode cap grinding and detection device comprises a first support, a visual instrument, a grinding assembly, a visual dustproof cover and a compressed air unit. The first support is arranged on an electrode cap grinding and detection device mounting plate of the frame body and is used for fixedly mounting the visual instrument, the visual dustproof cover, the grinding assembly and the compressed air unit. A blowing head is arranged at the side of the grinding assembly, a dust outlet is connected to the grinding assembly, and a dust collection barrel is opposite to the position of the dust outlet. The blowing head blows away the waste generated by grinding into the dust collection barrel through the dust outlet.

[0020] The visual instrument is used for detecting the wear condition of the electrode cap on the movable arm welding tong and the static arm welding tong sent by the welding mechanism and feeding the detection result to the central control system.

[0021] The visual dustproof cover is arranged on the visual instrument and can be opened or closed.

[0022] The grinding assembly is used for receiving instructions of the central control system, and controls the two-sided grinding knife to grind the wear and attachments on the electrode cap of the movable arm welding horn and the static arm welding horn in the welding mechanism according to the received instructions until the electrode cap on the movable arm welding horn and the static arm welding horn are concentric.

[0023] Further, the electrode cap automatic feeding and discharging device comprises a second support, a movable arm feeding assembly, a static arm feeding assembly, a discharging assembly, a collecting assembly and a compressed air unit, the second support is arranged on the automatic feeding and discharging device mounting plate of the frame body, the support movable arm feeding assembly, the static arm feeding assembly, the discharging assembly, the collecting assembly and the compressed air unit are fixedly installed on the second support, and springs are arranged on the movable arm feeding assembly and the static arm feeding assembly.

[0024] The compressed air unit is used for driving the discharging assembly to open the discharging port, the electrode cap of the movable arm welding horn on the welding mechanism moves to the discharging port, the compressed air unit is vented to drive the discharging port to be closed, so that the electrode cap is locked, the welding mechanism is retreated to drive the electrode cap on the movable arm welding horn to be separated, the blowing head starts the continuous blowing function, the compressed air unit drives the discharging assembly to open the discharging port, and the waste electrode cap is discharged by the compressed air of the blowing head; and the collecting assembly is used for collecting the waste electrode cap blown off by the discharging assembly.

[0025] Further, the safety protection system comprises a safety fence and a light curtain, the safety fence is arranged outside the spot welding station, and the light curtain is arranged on the safety fence; the safety fence is used for preventing abnormal entry of foreign matters into the production area, the light curtain is used for detecting the entry of foreign matters into the production area from the entrance, and timely feeds back a warning signal, and the central control system receives the signal and outputs a safety protection instruction.

[0026] The effect of the present application is that the disclosed flexible intelligent spot welding station has the following advantages: (1) high integration and automation: integrating mechanical, electrical, pneumatic and intelligent technologies into an integrated type, forming two sets of spatial motion chains through the mechanical relationship between the frame body, flexible turntable and spot welding robot system, developing flexible turntable technology based on the mixed mode of gear transmission and pneumatic transmission, and adopting offset type driving structure; the frame body is designed based on the functional modular structure design method, and adopts a three-dimensional structure; the control system of the equipment is centrally managed, and the scheduling instructions are uniformly sent. The pipe splicing technology of the traditional water cooling system, manual and specific machine dominated resistance spot welding mode can be completely replaced, personal injury caused by operation process is avoided; waiting is not needed, the production process is continuous and smooth, the production efficiency is improved, the product consistency is improved, the production process stability is ensured, the phenomenon of long changeover time and production stop due to people is eliminated; the land occupation of the fixture station is reduced, and the production site utilization rate is improved; the gap in the field of this technology in the automotive industry is filled.

[0027] (2) strong compatibility: the open interface enables the automatic detection unit to be compatible, and the automatic production line to be integrated, forming linkage.

[0028] (3) compact structure, small equipment size, easy to carry and install, simple operation, large carrying weight, and can be widely applied to the field of intelligent resistance spot welding of white body parts in the automotive industry.

[0029] (4) the frame body, flexible turntable and spot welding robot system form two sets of spatial motion chains, and the pneumatic technology is incorporated, so that the linkage and cooperation functions in the welding process are realized. The performance is more stable, the compatible range is wider, the welding is more flexible, the efficiency is higher, and the changeover is more convenient.

[0030] (5) the electrode grinding and detection device and the electrode automatic feeding and discharging device realize the core functions of automatic detection, grinding and electrode cap automatic feeding and discharging, the surface of the moving and static arm electrode cap is corrected to be smooth and concentric, the structure of replacing the electrode cap is novel and ingenious, the equipment cost is reduced, and the compatible range of the equipment is improved.

[0031] (6) the steel pipe of the lightweight sealed water cooling system of the present application adopts a thin-walled steel pipe, reducing the manufacturing cost by about 30%, improving the performance-price ratio of the equipment. The steel pipe joint adopts a 55° conical sealing thread technology, improving the pipe sealing performance and the cooling performance of the equipment. The steel pipe joint adopts a rolled thread, accelerating the transformation and application of green technology, protecting the loss of the steel pipe surface corrosion protection technology, improving the thread strength by 50%, and prolonging the service life of the equipment. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 a three-dimensional view of an intelligent spot welding station shown in the embodiments of the present application;

[0033] Figure 2 A top view of an intelligent spot welding station according to an embodiment of the present application;

[0034] Figure 3 A structural schematic view of a frame body 1 in an intelligent spot welding station according to an embodiment of the present application;

[0035] Figure 4 A structural schematic view of a flexible turntable 2 in an intelligent spot welding station according to an embodiment of the present application;

[0036] Figure 5 A structural schematic view of a workbench 203, a stop block 207, a cylindrical pin 208, a cylinder 209, a connecting rod 2011 and a junction box 2012 in an intelligent spot welding station according to an embodiment of the present application;

[0037] Figure 6 A structural schematic view of a spot welding robot system 3 in an intelligent spot welding station according to an embodiment of the present application;

[0038] Figure 7 A structural schematic view of a welding mechanism 5 in an intelligent spot welding station according to an embodiment of the present application;

[0039] Figure 8 A structural schematic view of a lightweight sealed water cooling system 7 in an intelligent spot welding station according to an embodiment of the present application;

[0040] Figure 9 A structural schematic view of an electrode cap grinding and detecting device 8 in an intelligent spot welding station according to an embodiment of the present application;

[0041] Figure 10 A structural schematic view of an electrode cap automatic feeding and discharging device 9 in an intelligent spot welding station according to an embodiment of the present application;

[0042] Figure 11 A right view of an electrode cap automatic feeding and discharging device 9 in an intelligent spot welding station according to an embodiment of the present application;

[0043] Figure 12 A structural schematic view of a safety protection system 10 in an intelligent spot welding station according to an embodiment of the present application;

[0044] Figure 13 A structural schematic view of a central control system 11 in an intelligent spot welding station according to an embodiment of the present application;

[0045] Figure 14 A structural schematic view of a cylindrical pin 208 in an intelligent spot welding station according to an embodiment of the present application;

[0046] Wherein: 1-frame body, 2-flexible turntable, 3-spot welding robot system, 4-touch screen system, 11-central control system, 5-welding mechanism, 6-compressed air unit, 10-safety protection system, 7-lightweight sealed water cooling system, 8-electrode cap grinding and detection device, 9-electrode cap automatic feeding and discharging device, 101-base, 102-turntable mounting plate, 103-positioning pin, 104-spot welding robot base mounting plate, 105-electrode cap grinding and detection device mounting plate, 106-electrode cap automatic feeding and discharging device mounting plate, 107-foot support, 108-top platform, 201-first vertical column, 202-second vertical column, 203-workbench, 204-guide plate, 205-gimbal ball, 206-limiting block, 207-stop block, 208-cylindrical pin, 209-cylinder assembly, 2010-cylinder support, 2011-connecting rod, 2012-junction box, 2013-servo motor, 2014-reducer, 2015-bearing, 301-spot welding robot base, 302-spot welding robot, 501-moving arm welding tongs, 502-static arm welding tongs, 503-servo motor, 504-transformer, 701-steel pipe, 702-steel pipe joint, 703-stainless steel ball valve, 704-filter valve, 705-water flow sensor, 706-water cut-off valve, 707-backwater cylinder, 708-electromagnetic valve, 709-pressure switch, 7010-slow pneumatic valve, 7011-gas source triad, 801-first support, 802-vision instrument, 803-grinding assembly, 804-vision dust cover, 10000-fixture clamp, 20000-part product, 30000-electrode cap, 40000-blowing head, 50000-dust outlet, 60000-dust collection barrel, 901-second support, 902-moving arm feeding assembly, 903-static arm feeding assembly, 904-discharging assembly, 905-material collecting assembly, 70000-discharging port, 1001-safety fence, 1002-light curtain, 1101-central control system master control machine, 1102-first welding signal processor, 1103-second welding signal processor, 1104-power controller. DETAILED DESCRIPTION

[0047] The application will be further described below in conjunction with the drawings and specific embodiments.

[0048] Example One

[0049] As shown in Figure 1 and Figure 2 , the embodiment of the application shows a flexible intelligent spot welding station, which includes a frame body 1, a flexible turntable 2, a spot welding robot system 3, a touch screen system 4, a central control system 11, a welding mechanism 5, a compressed air unit 6, a safety protection system 10, a lightweight sealed water cooling system 7, an electrode cap grinding and detection device 8, and an electrode cap automatic feeding and discharging device 9.

[0050] Each component is arranged on the frame body 1, and the two sets of electrode cap grinding and detection devices 8 and the electrode cap automatic feeding and discharging devices 9 are symmetrically distributed on both sides of the spot welding robot system 3. The two sets of welding mechanisms 5 are arranged on the spot welding robot system 3, and the electrode cap grinding and detection devices 8 and the electrode cap automatic feeding and discharging devices 9 are arranged between the spot welding robot system 3 and the flexible turntable 2.

[0051] The tool clamp 10000 is positioned and clamped on the flexible turntable 2 along the guide plate 204, and the part product 20000 is positioned and clamped on the tool clamp 10000. Four part products and tool clamps can be installed at a time, and the spot welding robot system 3 drives the welding mechanism 5 to perform resistance spot welding. After the spot welding of the part product 20000 of this type is completed, other types of part products 20000 and tool clamps 10000 can be replaced. The flexible turntable 2 performs flexible adjustment through the change of the double workbench surface stopper and the pneumatic, so as to fix clamps of different sizes. The touch screen system 4 sends matching instructions to the central control system 11 for unified scheduling. The lightweight sealed water cooling system 7 adjusts the temperature of the welding mechanism 5 during the welding process to be always between the stable operation values of the equipment.

[0052] The electrode cap grinding and detection device 8 is used to detect the surface attachments, wear state and correction of the two electrode caps 30000 of the moving and static arms of the welding mechanism 5, so as to ensure the welding quality during the operation of the welding mechanism 5. When the electrode cap grinding and detection device 8 detects that the surface wear of the electrode cap 30000 exceeds the grinding range value, the central control system 11 sends an electrode replacement instruction. After receiving the instruction, the spot welding robot system 3 moves the welding mechanism 5 to the electrode cap automatic feeding and discharging device 9 to perform automatic discharging, pneumatic discharging, feeding and fixing of the electrode cap 30000. The waste gas generated during the spot welding process is collected, filtered and discharged. The safety of the production process is ensured by the safety protection system 10. The whole process operation execution flow instruction is controlled by the central control system 11 for unified scheduling, without the need for manual and specific machine guidance. The function is completely replaced by manual and specific machine, and the performance is better than manual and specific machine guidance. The occurrence of product quality inconsistency and personal injury safety risk is avoided, the production efficiency is improved, and the intelligent level of the lightweight body-in-white manufacturing industry is improved.

[0053] As Figure 3As shown, the frame body 1 is one of the important components of the flexible intelligent spot welding station. It is divided into upper and lower layers. The lower layer is the functional area, supporting various functional equipment and ensuring its installation space and performance stability. The upper layer is the data scheduling center area, ensuring the installation space and operating environment of the instruments and contributing to their performance stability. It mainly includes two bases 101, a turntable mounting plate 102, positioning pins 103, a spot welding robot base mounting plate 104, an electrode cap grinding and testing device mounting plate 105, an electrode cap automatic loading and unloading device mounting plate 106, a foot bracket 107, and a top platform 108. The base 101 is "I" shaped, which provides maximum space to ensure the reliable mechanical operation of the flexible turntable's double-layer four-station design, while facilitating the loading and unloading of parts 20,000 and tooling fixtures 10,000, thus improving the safety protection factor.

[0054] The base 101 is mainly welded from square tubes and is used to arrange auxiliary lines such as cables, wires, and air pipes by taking advantage of the hollow nature of the square tubes and the additional slots, so as to prevent the auxiliary lines from interfering with other equipment. The two bases 101 are arranged opposite each other, and two foot brackets 107 of equal height extend upward from each of the two bases 101. A top platform 108 is set on the top of the four foot brackets 107. Four turntable mounting plates 102 and positioning pins 103 are all mounted on the base 101 to ensure the installation accuracy of the two flexible turntables 2. Two spot welding robot base mounting plates 104 are positioned between the two bases 101, and positioning pins 103 are set around the two spot welding robot base mounting plates 104. The two spot welding robot base mounting plates 104 and their positioning pins 103 are used to ensure the installation accuracy of the two spot welding robot systems 3 and their relative relationship with the flexible turntables 2, which is beneficial to the linkage function and the stability of spot welding performance. The electrode cap grinding and testing device mounting plate 105 is positioned between the two bases 101, and positioning pins 103 are set around the electrode cap grinding and testing device mounting plate 105. The electrode cap grinding and testing device mounting plate 105 and the positioning pins 103 are used to ensure the installation accuracy of the two spot welding robot systems 3 and their relative relationship with the flexible turntables 2, which is beneficial to the linkage function and the stability of spot welding performance. The installation accuracy of the grinding and testing device 8, and its relative mechanical relationship with the welding mechanism 5, are conducive to improving the welding quality of the product. The electrode cap automatic loading and unloading device mounting plate 106 is set between the two bases 101, and positioning pins 103 are set around the electrode cap automatic loading and unloading device mounting plate 106. The electrode cap automatic loading and unloading device mounting plate 106 and the positioning pins 103 are used to ensure the installation accuracy of the electrode cap automatic loading and unloading device 9, and its relative mechanical relationship with the welding mechanism 5, which is conducive to improving production efficiency. The top platform 108 is used to install precision instruments for data acquisition and processing of the central control system 11, reducing the production floor space and improving the utilization rate of the production site. The foot bracket 107 is used to adjust the height of the flexible intelligent spot welding station frame body 1, adapt to the connecting equipment, and then fix it with bolts.

[0055] like Figure 4 , Figure 5 as well as Figure 14As shown, the flexible rotary table 2 is one of the important mechanisms of the flexible intelligent spot welding station, which includes two flexible rotary tables 2. The flexible rotary table 2 includes a first vertical column 201, a second vertical column 202, a workbench 203, a guide plate 204, a universal ball 205, a limiting block 206, a stop block 207, a cylindrical pin 208, a cylinder assembly 209, a cylinder support 2010, a connecting rod 2011, a junction box 2012, a servo motor 2013, a speed reducer 2014, a bearing 2015, and the like. The flexible rotary table 2 is of a split structure, which is composed of two independent components of a driving end and a driven end to form an open-chain mechanism. The two components are concentrically arranged with the first vertical column 201 and the second vertical column 202 as the main body structure and with the workbench 203 as the centerline of rotation as the reference. The two components are connected to form a closed-chain mechanism through a tooling fixture 10000. The double table in the workbench 203 is used to accommodate various types of tooling fixtures 10000 with a length of 1600mm-2000mm and a width of 700mm. The tooling fixture 10000 is positioned and clamped on the flexible rotary table 2 along the guide plate 204, and the part product 20000 is positioned and clamped on the tooling fixture 10000. The bevel edges of the four guide plates 204 are used to ensure the quick positioning of the tooling fixture 10000. The straight edges of the four guide plates 204 are used to ensure the quick positioning of the tooling fixture 10000. The spherical surface supports of the multiple sets of universal balls 205 are used to support the bottom surface of the bottom plate of the tooling fixture 10000 to prevent resistance caused by adsorption force during type changing. The multiple sets of limiting blocks 206 are used to ensure the final safety limiting of the tooling fixture 10000. The guide holes of the four stop blocks 207 are used to ensure the running accuracy of the extension and retraction of the cylindrical pins 208. The four cylindrical pins 208 are used to ensure the quick positioning of the tooling fixture 10000, and the cylindrical pin 208 stop edge is used to ensure the centering of the tooling fixture 10000 and the part product 20000. The cylinder assembly 209, the cylinder support 2010, the connecting rod 2011, the cylindrical pin 208, and the compressed air unit 6 form a parallel combined mechanism, which is driven by the compressed air unit 6 to synchronously and concentrically extend and retract the two ends of the cylindrical pin 208 to ensure the centering accuracy of the tooling fixture 10000 and the part product 20000. The junction box 2012 is used to supply the modular quick plug technology. The servo motor 2013, the speed reducer 2014, the workbench 203 of the driving end, the tooling fixture 10000, the workbench 203 of the driven end, the bearing 2015, and the like form a series combined mechanism. The servo motor 2013 and the speed reducer 2014 provide a driving source to drive the rotary mechanical movement of the workbench 203 of the driving end, and drive the tooling fixture 10000 and the workbench 203 of the driven end to synchronously move. The rigidity and installation accuracy of the first vertical column 201 and the second vertical column 202 are used to ensure that the workbenches 203 at both ends do not have symptoms such as jamming, shaking, and eccentricity during mechanical movement, and to ensure the load capacity of the flexible rotary table 2.

[0056] As Figure 6 and Figure 13As shown, the spot welding robot system 3 is one of the important mechanisms of the flexible intelligent spot welding station, which is composed of two spot welding robots 302 and a spot welding robot base 301, and is distributed on both sides of the flexible intelligent spot welding station body, and is independently controlled by the first welding signal processor 1102 and the second welding signal processor 1103, and is uniformly deployed by the central control system master control machine 1101, so as to realize the technical characteristics of cooperation and flexibility. The spot welding robot base 301 is fixed on the spot welding robot base mounting plate 104 in the frame body 1, which ensures the installation accuracy of the two spot welding robots 302, enhances the basic stability of the spot welding robots 302, and improves the arm range of the spot welding robots 302 and the self-weight and load of the spot welding robots 302. The six-axis freedom of the spot welding robot 302 is used to ensure the mechanical relationship between the posture of the spot welding robot 302 and the product posture, and to ensure the cooperation and integration of the two spot welding robots 302.

[0057] As shown in Figure 7 The welding mechanism 5 is one of the important mechanisms of the flexible intelligent spot welding station, which includes two welding mechanisms 5, and the welding mechanism 5 includes a movable arm welding tong 501, a static arm welding tong 502, a servo motor 503 and a transformer 504. The welding mechanism 5 is located at the end of the spot welding robot 302. The movable arm welding tong 501 and the static arm welding tong 502 are designed in pairs to convert the instructions output by the servo motor 503 into opening and closing mechanical movements, and correspondingly ensure that the electrode cap 30000 of the movable arm welding tong 501 and the static arm welding tong 502 generates the effect of welding heat connection and blocking welding. The servo motor 503 is used to receive the instructions of the central control system 11 and output the received instructions to the movable arm welding tong 501 and the static arm welding tong 502 in real time to drive the corresponding mechanical movement, continuously perform the standard welding action, and ensure the welding seam forming quality of the automobile part product 20000. The transformer 504 is used to reduce the input voltage from the outside and increase the output current to generate enough heat for soldering. The inner cavity of the movable arm welding tong 501 and the static arm welding tong 502 forms a circulating cooling waterway to ensure the welding seam forming quality and eliminate the working condition risk.

[0058] The compressed air unit 6 is one of the important mechanisms of the flexible intelligent spot welding station, acts as the "blood vessel" of the flexible intelligent spot welding station, is respectively arranged at the corresponding positions of the flexible turntable 2, the electrode cap grinding and detecting device 8 and the electrode cap automatic feeding and discharging device 9 and the like components, is independently controlled, and is uniformly allocated by the central control system 11. The compressed air unit 6 is used for outputting compressed air medium, guarantees the gas use demand of the energy conversion process of the tool clamp 10000 in the flexible turntable 2, and guarantees the accurate opening and positioning of the tool clamp 10000. The compressed air unit 6 is used for outputting compressed air medium, guarantees the gas use demand of the energy conversion process in the electrode grinding and detecting device 8, and ensures the stable opening of the visual protective cover. The compressed air unit 6 is used for outputting compressed air medium, guarantees the gas use demand of the energy conversion process in the electrode grinding and detecting device 8, ensures the rapid separation of the electrode grinding waste and enters the collection container. The compressed air unit 6 is used for outputting compressed air medium, guarantees the gas use demand of the energy conversion process in the electrode cap automatic feeding and discharging device 8, and ensures the rapid separation of the electrode cap after the excessive wear of the motor cap is discharged.

[0059] As Figure 8As shown, the lightweight sealed water cooling system 7 is one of the core components of the energy-saving method of the flexible intelligent spot welding station. The lightweight sealed water cooling system 7 eliminates the damage to the equipment and the pollution to the environment caused by water leakage of the flexible intelligent spot welding station, reduces the steel consumption of the flexible intelligent spot welding station, and reduces the manufacturing cost, and creates green manufacturing technology. The lightweight sealed water cooling system 7 includes a steel pipe 701, a steel pipe joint 702, a stainless steel ball valve 703, a filter valve 704, a water flow sensor 705, a water cut-off valve 706, a water return cylinder 707, two electric control electromagnetic valves 708, a pressure switch 709, a slow pneumatic valve 7010, a gas source three-way piece 7011, and a compressed air unit 6. The main cooling process route of the lightweight sealed water cooling system 7 is that the cooling liquid enters the water inlet, passes through the stainless steel ball valve 703 and the filter valve 704, and is divided into two water paths. One enters the welding mechanism 5 to the water outlet. The other enters the water cut-off valve 706 and is divided into two water paths. One enters the transformer 504, and then flows to the water cut-off valve 706, the water flow sensor 705, and then converges to the stainless steel ball valve 703 to the water outlet. The other flows to the movable arm welding tong 501 and the static arm welding tong 502 to the pressure switch 709, one of which flows to the water return cylinder 707, and the other of which converges to the water cut-off valve 706, the water flow sensor 705, and then converges to the stainless steel ball valve 703 to the water outlet. The 55° sealed pipe thread conical thread technology is used to ensure that the threads at the splicing position of the steel pipe 701 and the steel pipe joint 702 are sealed and self-locked. The cold rolling technology is used to ensure that the steel pipe wall is extended to form a 55° sealed pipe thread conical thread. The cold rolling thread process does not produce waste and smoke. The cold rolling technology is used to ensure that the wall thickness of the pipe main material can be reduced by 30%, the thread strength of the steel pipe end is increased by 50%, the loss of zinc elements on the surface of the steel pipe is prevented, the thread tooth tip is prevented from breaking, and the manufacturing cost is reduced. The overall equipment competitiveness is improved.

[0060] As Figure 9As shown, the electrode cap grinding and detection device 8 is one of the important mechanisms of the flexible intelligent spot welding station, including a first support 801, a vision instrument 802, a grinding assembly 803, a vision dust cover 804, and a compressed air unit 6. The electrode cap grinding and detection device 8 is arranged between the spot welding robot system 3 and the flexible turntable 2. The first support 801 is arranged on the electrode cap grinding and detection device mounting plate 105 to ensure the installation accuracy of the electrode cap grinding and detection device 8 and enhance the consistency of the grinding surface of the electrode cap 30000. The first support 801 is used to support the vision instrument 802, the vision dust cover 804, the grinding assembly 803, and the compressed air unit 6 to ensure their stability. The vision dust cover 804 is arranged on the vision instrument 802 and can be opened or closed to ensure the stability of the vision performance. The vision instrument 802 is used to detect the wear condition of the electrode cap 30000 on the moving arm welding tong 501 and the static arm welding tong 502 sent by the welding mechanism 5 and feed a signal to the central control system 11. The grinding assembly 803 is used to receive the instruction of the central control system 11 and then control the two-sided grinding knives to grind the wear and attachments of the electrode cap 30000 on the moving arm welding tong 501 and the static arm welding tong 502 in the welding mechanism 5 to the same concentricity. The air blowing head 40000 is arranged on the side of the grinding assembly 803. The dust outlet 50000 is connected with the grinding assembly 803. The dust collection barrel 60000 is opposite to the position of the dust outlet 50000. The waste generated by the grinding is blown away by the air blowing head 40000, flows into the dust collection barrel 60000 through the dust outlet 50000, and realizes the stable performance of the welding process.

[0061] As Figure 10 and Figure 11As shown, the electrode cap automatic feeding and discharging device 9 is one of the important mechanisms of the flexible intelligent spot welding station, and the electrode cap automatic feeding and discharging device 9 includes a second support 901, a movable arm feeding assembly 902, a static arm feeding assembly 903, a discharging assembly 904, a material collecting assembly 905, a compressed air unit 6 and the like, and is arranged between the spot welding robot system 3 and the flexible turntable 2. The second support 901 is arranged on the automatic feeding and discharging device mounting plate 106 to ensure the installation accuracy of the electrode automatic feeding and discharging device 9, and also ensure the installation accuracy of the electrode cap 30000 of the movable arm welding tong 501 and the static arm welding tong 502. The support 1 is used to support the movable arm feeding assembly 902, the static arm feeding assembly 903, the discharging assembly 904, the material collecting assembly 905 and the compressed air unit 6 to ensure the stability thereof. The compressed air unit 6 is used to drive the discharging assembly 904 to open the discharging port 70000, and the electrode cap 30000 of the movable arm welding tong 501 on the welding mechanism 5 is moved to the discharging port 70000. The compressed air unit 6 is deflated to drive the discharging port 70000 to be closed, so as to lock the electrode cap 30000. The welding mechanism 5 is retreated to drive the electrode cap 30000 on the movable arm welding tong 501 to be separated. The blow head 40000 is started to continuously blow air. The compressed air unit 6 drives the discharging assembly 904 to open the discharging port 70000, and the waste electrode cap 30000 is discharged by the compressed air of the blow head 40000. The compressed air unit 6 is used to drive the discharging assembly 904 to open the discharging port 70000, and the electrode cap 30000 on the static arm welding tong 502 on the welding mechanism 5 is moved to the discharging port 70000. The compressed air unit 6 is deflated to drive the discharging port 70000 to be closed, so as to lock the electrode cap 30000. The welding mechanism 5 is retreated to drive the electrode cap 30000 on the static arm welding tong 502 to be separated. The blow head 40000 is started to continuously blow air. The compressed air unit 6 drives the discharging assembly 904 to open the discharging port 70000, and the waste electrode cap 30000 is discharged by the compressed air of the blow head 40000. The elasticity of the spring of the movable arm feeding assembly 902 is used to ensure that the new electrode cap 30000 is sent to the feeding port, to ensure that the electrode cap 30000 is timely and accurately fed when the movable arm welding tong 501 of the welding mechanism 5 is moved to the feeding port, and to ensure that the material is supplemented. The elasticity of the spring of the static arm feeding assembly 903 is used to ensure that the new electrode cap 30000 is sent to the feeding port, to ensure that the electrode cap 30000 is timely and accurately fed when the static arm welding tong 502 of the welding mechanism 5 is moved to the feeding port, and to ensure that the material is supplemented. The material collecting assembly 905 ensures that the waste electrode cap 30000 blown off by the discharging assembly 904 is uniformly collected, so as to form a unified treatment.

[0062] As Figure 12As shown, the safety protection system 10 is one of the important mechanisms of the flexible intelligent spot welding station, including safety fence 1001 and light curtain 1002 and other components, the safety fence 1001 is arranged outside the flexible intelligent spot welding station, to ensure the production safety of the functional area in the flexible intelligent spot welding station. The light curtain 1002 is arranged on the safety fence 1001, the safety fence 1001 is used to prevent the abnormal entry of foreign objects into the production area, and a plurality of light curtains 1002 are used to detect the entry of foreign objects into the production area from the entrance and exit in the production process, and timely feedback warning signals, and the central control system 11 receives the signals and outputs safety protection instructions.

[0063] As shown in the figure, Figure 13 As shown, the central control system 11 is one of the core mechanisms of the flexible intelligent spot welding station, including central control system master control machine 1101, first welding signal processor 1102, second welding signal processor 1103 and power controller 1104 and other components, and the central control system 11 is located in the data scheduling center area of the top platform 108 of the frame body 1. The central control system master control machine 1101 is used to ensure the centralized collection of instructions and unified allocation, to ensure the linkage and cooperation between devices, and the integration with manual interaction. The first welding signal processor 1102 and the second welding signal processor 1103 are respectively used to ensure the signal instruction input and output of the spot welding robot 302 and the welding mechanism 5, and timely convert into stable mechanical movement, to ensure the stability of the welding performance. The power controller 1104 is used to ensure the continuous power supply demand of the flexible intelligent spot welding station, and ensure the safety of the power energy in the production process.

[0064] In summary, the flexible intelligent spot welding station disclosed by the application has high integration and full-process automation, can completely replace the pipeline splicing technology of the traditional water cooling system, manual and specific machine dominated resistance spot welding mode, avoid personal injury caused by operation process; without waiting, make the production process continuous and smooth, improve the production efficiency; improve the product consistency, ensure the stability of the production process, eliminate the phenomenon of long change type time and production stop due to people; reduce the floor area of the fixture station, improve the utilization rate of the production site; fill the technical gap in this field of the automobile industry.

[0065] The device described in the application is not limited to the embodiments described in the specific embodiments, and other embodiments can be derived by those skilled in the art according to the technical solutions of the application, which also belong to the technical innovation range of the application.

Claims

1. A flexible intelligent spot welding station characterized by: The spot welding station comprises a frame body, a flexible turntable, a spot welding robot system, a touch screen system, a central control system, a welding mechanism, a compressed air unit, a safety protection system, a lightweight sealed water cooling system, an electrode cap grinding and detection device, and an electrode cap automatic feeding and discharging device, each component is arranged on the frame body, two groups of the electrode cap grinding and detection device and the electrode cap automatic feeding and discharging device are symmetrically distributed on both sides of the spot welding robot system, two groups of the welding mechanism are arranged on the spot welding robot system, and the electrode cap grinding and detection device and the electrode cap automatic feeding and discharging device are arranged between the spot welding robot system and the flexible turntable; The tool fixture is positioned and clamped on the flexible turntable along the guide plate of the flexible turntable, the part product is positioned and clamped on the tool fixture, the spot welding robot system drives the welding mechanism to perform resistance spot welding, after the spot welding of the part product of the type is completed, other types of part products and tool fixtures can be replaced, the flexible turntable is flexibly adjusted through the change of the double workbench surface stop and the pneumatic, so as to fix different sizes of fixtures, the touch screen system sends matching instructions to the central control system for unified scheduling, and the lightweight sealed water cooling system adjusts the welding mechanism to execute corresponding instructions, so as to ensure that the temperature in the welding process is always between the stable operation values of the equipment; The electrode cap grinding and detection device is used for detecting the attachment and wear state of the two electrode caps of the dynamic and static arms of the welding mechanism and correcting the two electrode caps to be concentric, when the detection evaluation result is that the surface wear of the electrode cap exceeds the grinding range value, the central control system sends an electrode replacement instruction, the spot welding robot system moves the welding mechanism to the electrode cap automatic feeding and discharging device after receiving the instruction, and performs an electrode cap process action, waste gas generated in the spot welding process is all collected, stored, filtered and discharged, and the safety protection system is used for production safety protection; The lightweight sealed water cooling system comprises a steel pipe, a steel pipe joint, a stainless steel ball valve, a filter valve, a water flow sensor, a water cut-off valve, a water return cylinder, two electrically-controlled electromagnetic valves, a pressure switch, a slow pneumatic valve, a gas source three-way joint and a compressed air unit, cooling liquid is divided into two water routes after the stainless steel ball valve and the filter valve from the water inlet, one water route is led to the welding mechanism to the water outlet; the other water route is led to the water cut-off valve, and then divided into two water routes, one water route is led to the transformer, and then flows to the water cut-off valve, the water flow sensor and the stainless steel ball valve to the water outlet; the other water route flows to the dynamic arm welding tong and the static arm welding tong to the pressure switch, one water route flows to the water return cylinder, and the other water route flows to the water cut-off valve, the water flow sensor and the stainless steel ball valve to the water outlet.

2. The flexible intelligent spot welding station of claim 1, wherein: The frame body is divided into upper and lower layers, the lower layer is a functional area for providing mounting space for various components, and the upper layer is a data scheduling center area, the frame body includes two bases oppositely arranged, a plurality of equal-height foot supports extending upward from the two bases, a top platform is arranged at the top of the foot supports, the height of the frame body is adjusted by adjusting the height of the foot supports, the height of the frame body is adapted to the connection equipment, the frame body is fixed by bolts, a plurality of mounting plates are arranged on the bases, and mounting grooves are arranged around the mounting plates to fix and mount various components.

3. The flexible intelligent spot welding station of claim 2, wherein: The flexible rotary table is a split structure, and includes a first stand, a second stand, a workbench, a guide plate, a universal ball, a limiting block, a stop block, a cylindrical pin, a cylinder assembly, a cylinder support, a connecting rod, a junction box, a servo motor, a speed reducer, and a bearing, which are composed of a driving end and a driven end to form an open-chain mechanism, the two parts are concentrically arranged with the first stand and the second stand as the main structure and the workbench rotation center line as the reference, and the two parts are connected into a closed-chain mechanism through a tool clamp; The inclined edge of the guide plate is used to ensure the quick positioning of the tool clamp; the straight edge of the guide plate is used to ensure the quick positioning of the tool clamp; the spherical support of the universal ball is used to support the bottom surface of the tool clamp bottom plate to reduce the change resistance; the limiting block is used to safely limit the tool clamp; the stop block guide hole is used to ensure the running accuracy of the cylindrical pin; the cylindrical pin is used to ensure the quick positioning of the tool clamp, and the cylindrical pin stop edge is used to center the tool clamp and the part product; The cylinder assembly, the cylinder support, the connecting rod, the cylindrical pin, and the compressed air unit form a parallel combined mechanism, which is driven by the compressed air unit to synchronously and concentrically extend and retract the two-end cylindrical pins to ensure the centering accuracy of the tool clamp and the part product; The junction box is used for modular quick insertion, and the servo motor, the speed reducer, the workbench of the driving end, the tool clamp, the workbench of the driven end, and the bearing form a series combined mechanism, which is driven by the servo motor and the speed reducer to provide a driving source to drive the rotary mechanical movement of the workbench of the driving end, and to drive the tool clamp and the workbench of the driven end to synchronously move.

4. The flexible intelligent spot welding station of claim 3, wherein: Two point welding robot systems are distributed on both sides of the point welding station and are independently controlled by a first welding signal processor and a second welding signal processor, the point welding robot system includes a point welding robot and a point welding robot base, and the point welding robot base is fixed on the point welding robot base mounting plate in the frame body.

5. The flexible intelligent spot welding station of claim 4, wherein: The spot welding station comprises two welding mechanisms, the welding mechanisms comprising a movable arm welding tong, a static arm welding tong, a servo motor and a transformer, the welding mechanisms being located at the end of the spot welding robot, the movable arm welding tong and the static arm welding tong being designed in pairs, the servo motor receiving instructions from the central control system and outputting the received instructions to the movable arm welding tong and the static arm welding tong in real time to drive corresponding mechanical movements, and accordingly controlling the electrode caps of the movable arm welding tong and the static arm welding tong to realize welding heat connection and block welding; the transformer reduces the input voltage and increases the output current to generate sufficient heat for resistance welding; the inner cavities of the movable arm welding tong and the static arm welding tong form a circulating cooling waterway.

6. The flexible intelligent spot welding station of claim 5, wherein: The compressed air units are respectively arranged at corresponding positions of the flexible turntable, the electrode cap grinding and detecting device and the electrode cap automatic feeding and discharging device, and are uniformly allocated and independently controlled by the central control system.

7. The flexible intelligent spot welding station of claim 6, wherein: The electrode cap grinding and detecting device comprises a first support, a visual instrument, a grinding assembly, a visual dustproof cover and a compressed air unit, the first support being arranged on an electrode cap grinding and detecting device mounting plate of the frame body, and being used for fixedly mounting the visual instrument, the visual dustproof cover, the grinding assembly and the compressed air unit, a blowing head being arranged at the side of the grinding assembly, a dust outlet being connected with the grinding assembly, and a dust collecting barrel being opposite to the position of the dust outlet, the blowing head blowing away the waste generated by grinding into the dust collecting barrel through the dust outlet; The visual instrument is used for detecting the wear condition of the electrode cap on the movable arm welding tong and the static arm welding tong sent by the welding mechanism, and feeding back the detection result to the central control system; The visual dustproof cover is arranged on the visual instrument, and can be opened or closed; The grinding assembly is used for receiving instructions from the central control system, and grinding the wear and attachments of the electrode cap on the movable arm welding tong and the static arm welding tong according to the received instructions, until the electrode caps on the movable arm welding tong and the static arm welding tong are concentric.

8. The flexible intelligent spot welding station of claim 7, wherein: The electrode cap automatic feeding and discharging device comprises a second support, a movable arm feeding assembly, a static arm feeding assembly, a discharging assembly, a collecting assembly and a compressed air unit, the second support being arranged on an automatic feeding and discharging device mounting plate of the frame body, and the movable arm feeding assembly and the static arm feeding assembly both being provided with springs; The compressed air unit is used for driving the discharging assembly to open the discharging port, the electrode cap of the movable arm welding tong on the welding mechanism moving to the discharging port, the compressed air unit being deflated to drive the discharging port to be closed, so as to lock the electrode cap, the welding mechanism retreating to drive the electrode cap on the movable arm welding tong to be separated, the blowing head being started to continuously blow air, the compressed air unit driving the discharging assembly to open the discharging port, and the discarded electrode cap being discharged by the compressed air of the blowing head; and the collecting assembly is used for collecting the discarded electrode cap blown off by the discharging assembly.

9. The flexible intelligent spot welding station of claim 8, wherein: The safety protection system comprises a safety fence and a light curtain, the safety fence is arranged outside the spot welding station, and the light curtain is arranged on the safety fence; the safety fence is used for preventing abnormal entry of foreign matters into the production area; the light curtain is used for detecting entry of foreign matters into the production area from the entrance and exit in the production process and feeding back a warning signal in time; and the central control system outputs a safety protection instruction after receiving the signal.

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