A visual guidance welding method for power cabinet

Abstract

The application discloses a power cabinet visual guidance welding method, and a welding positioner which comprises a base, a headstock column, a type rotating frame, a tailstock column, one end of the rotating frame is slidably connected with a bottom frame tool, the other end of the rotating frame is fixedly connected with a top frame tool, and the rotating frame, the bottom frame tool and the top frame tool form a type mounting position; the headstock column and the tailstock column are fixedly connected on the base, turnover mechanisms are respectively arranged on the bottom frame tool and the top frame tool, and a blanking mechanism is arranged on the base. The welding positioner is controlled by an electric cabinet platform, and the electric cabinet platform simultaneously controls a welding robot, a welding gun system and a laser guidance system. The power cabinet visual guidance welding workstation can guarantee continuous and stable welding and welding quality.

Description

Technical Field

[0001] This application relates to the field of welding equipment technology, and in particular to a visually guided welding method for power cabinets. Background Technology

[0002] Currently, most welding work in the power switchboard welding industry requires manual labor, and the scattered processes further increase the manual handling and transfer between multiple steps. While extensive manual labor offers greater flexibility, continuous work significantly impacts workers' ability to control welding quality, leading to poor weld formation. Repairing defects in one step ultimately affects not only welding quality but also overall production capacity.

[0003] By utilizing vision-guided automated welding technology, automated welding of power cabinets can be achieved, thereby solving the problems of time-consuming and cumbersome multi-process flow and difficulty in controlling welding quality during the welding process of power cabinets.

[0004] To achieve automated welding of power cabinets, it is necessary to develop a welding positioner suitable for power cabinets. Summary of the Invention

[0005] To address the problems of time-consuming and cumbersome multi-process workflows, excessive manual labor, difficulty in controlling welding quality, and unstable production capacity in the original manufacturing process of power cabinets, this application provides a welding positioner that can fix the loose components of the power cabinet and assist in achieving vision-guided automatic welding. The specific technical solution adopted is as follows: A welding positioner includes a base, a head frame column, a U-shaped rotating frame, and a tail frame column. A bottom frame fixture is slidably connected to one end of the rotating frame, and a top frame fixture is fixedly connected to the other end. The bottom and top frame fixtures are used to clamp the bottom and top of a power cabinet, respectively, and can also clamp the side away from the rotating frame. The rotating frame, bottom frame fixture, and top frame fixture form a U-shaped installation position. The head frame column and tail frame column are fixedly connected to the base, and drive the rotating frame to rotate. A flipping mechanism is provided on the bottom and top frame fixtures, and the flipping mechanism is used to clamp the front side of the power cabinet. A feeding mechanism is provided on the base.

[0006] Preferably, a servo motor is installed inside the head frame column, the servo motor is connected to a planetary gear reducer via a coupling, the planetary gear reducer is connected to the rotating frame via a slewing bearing, and a seated bearing is installed on the tail frame column, the seated bearing being connected to the other end of the rotating frame.

[0007] Preferably, the flipping mechanism includes a support base, a flipping cylinder, a flipping frame, and a clamping cylinder; the flipping cylinder is fixed to one side of the support base, the piston rod of the flipping cylinder is hinged to the first end of the flipping frame, the support base is hinged to the second end of the flipping frame, the first end and the second end of the flipping frame are located on the same side, a clamping cylinder is provided on the other side of the flipping frame, the clamping cylinder is located at the end away from the rotating frame, the flipping frame and the support base are connected by a connecting rod and a rotating shaft, and the support base is fixedly connected to the bottom frame fixture and the top frame fixture respectively.

[0008] Preferably, when the piston rod of the tilting cylinder extends, the tilting frame and the clamping cylinder tilt and lower around the connecting rod shaft; when the piston rod of the tilting cylinder retracts, the tilting frame and the clamping cylinder tilt and open around the connecting rod shaft.

[0009] Preferably, the feeding mechanism includes a feeding cylinder and a feeding crossbar; the feeding cylinder is hinged to the lower end of the feeding crossbar in the middle, and the lower ends of the feeding crossbar are connected to the base on both sides; the feeding crossbar is provided with a protective pad.

[0010] Preferably, the bottom frame fixture and the top frame fixture clamp the side of the power cabinet away from the rotating frame using several corner clamping cylinders.

[0011] This application also provides a power cabinet vision-guided welding workstation, which can achieve non-stop welding through the cooperation of the welding positioner and the welding robot; it includes at least one welding positioner as described in this application, as well as at least one welding robot, a laser guidance system, and a power cabinet platform; The welding robot includes a welding torch system and a six-axis robotic arm. The welding torch system includes an electric welding machine, a torch cleaner, and a welding torch fixed at the end of the six-axis robotic arm. The electric welding machine supplies power and gas to the welding torch. The laser guidance system includes an industrial smart camera and a laser emitter, and the laser guidance system is fixed to one side of the welding torch. The electrical cabinet platform integrates the control system of the welding workstation, including the control of the welding robot, the welding torch system, the laser guidance system, and the positioner.

[0012] Preferably, the number of the welding positioner and the welding robot is two.

[0013] This application also provides a visually guided welding method for power cabinets, including the following steps: S1 clamping process: After the various components of the power cabinet are assembled, they are pushed into the welding positioner. The moving bottom frame fixture presses the top and bottom of the assembled power cabinet to ensure the length dimension of the power cabinet. Then, the piston rod of the flipping cylinder in the flipping mechanism extends to clamp the power cabinet on the side away from the rotating frame. At the same time, several corner clamping cylinders on the bottom frame fixture and the top frame fixture clamp the power cabinet on the side away from the rotating frame. The small fins on the power cabinet are fixed to the corresponding size position by magnetic adsorption. S2 Rotation Process: The head frame column is driven by a servo motor to drive a planetary gear reducer. The end of the planetary gear reducer is connected to a small gear to transmit power to the slewing bearing. The slewing bearing drives the rotating frame to rotate, and at the same time drives the clamped power cabinet to rotate to an angle suitable for welding by the welding robot. S3 Welding Process: The welding positioner inputs the angle adjustment completion signal to the electrical cabinet platform. The electrical cabinet platform inputs the welding signal to the welding robot. The laser emitter illuminates the weld seam, forming a breakpoint. The industrial intelligent camera identifies the breakpoint coordinates, fits the weld seam trajectory, and transmits the data to the electrical cabinet platform. The electrical cabinet platform sends welding instructions to the welding robot based on the fitted weld seam position. The welding robot performs welding according to the instructions. After welding is completed, the industrial intelligent camera inputs a welding completion signal to the electrical cabinet platform. The electrical cabinet platform inputs a stop welding signal to the welding robot. After detecting that the welding robot has stopped welding, the industrial intelligent camera inputs a reset signal to the welding robot. S4 cycle process: Repeat S2 and S3 multiple times until the entire power cabinet is welded; S5 unloading process: All cylinders on the tooling are reversing and released, the bottom frame tooling retracts, and the unloading crossbar is lifted by the unloading cylinder on the welding positioner base, pushing out the power cabinet.

[0014] The beneficial effects of this application are: 1) The clamping and flipping mechanism can clamp the power cabinet and assist the rotating frame in rotating the power cabinet; 2) During the welding process, the unloading crossbar lies flat and does not interfere with the power cabinet; when welding is completed, the unloading crossbar flips up to push the power cabinet out for unloading. 3) The top frame fixture and the bottom frame fixture are clamped together, and the rotating frame drives the power cabinet to rotate in order to cooperate with the welding robot for welding; 4) Continuous and stable welding is ensured by alternating clamping with two welding positioners; 5) Saves process: Each component can be transported directly to the vicinity of the workstation and assembled into a power cabinet frame while waiting for loading. After the components are assembled, there is no need for workers to spot weld them before welding, saving a lot of welding time. 6) Low proportion of manual labor: Not only does it save on processes, but the entire process from individual components to the welding of the power cabinet frame only requires manual operation during loading and unloading. The welding process does not require manual participation, which greatly reduces the proportion of manual labor in the product manufacturing process. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the power cabinet vision-guided welding workstation described in this application. Figure 1 ; Figure 2 This is a schematic diagram of the welding positioner described in this application; Figure 3 This is a schematic diagram of the structure of the welding positioner (excluding the bottom frame fixture, the flipping mechanism, the top frame fixture, and the C-shaped rotating frame) described in this application. Figure 1 ; Figure 4 This is a schematic diagram of the structure of the welding positioner (excluding the bottom frame fixture, the flipping mechanism, the top frame fixture, and the C-shaped rotating frame) described in this application. Figure 2 ; Figure 5 This is a schematic diagram of the top frame tooling structure described in this application; Figure 6 This is a schematic diagram of the structure of the flipping mechanism described in this application; Figure 7 This is a schematic diagram of the structure of the tilting mechanism described in this application when the cylinder is extended; Figure 8 This is a schematic diagram of the structure of the tilting mechanism described in this application when the cylinder retracts; Figure 9 This is a schematic diagram of the feeding mechanism described in this application; Figure 10 This is a schematic diagram of the structure of the power cabinet vision-guided welding workstation described in this application. Figure 2 .

[0016] In the diagram: 1. Welding robot, 2. Electrical cabinet platform, 3. Welding positioner, 301. Head frame column, 302. Bottom frame fixture, 303. Tilting mechanism, 3031. Tilting cylinder, 3032. Connecting rod shaft, 3033. Tilting frame, 3034. Clamping cylinder, 3035. Support base, 304. Top frame fixture, 305. Tail frame column, 306. Unloading mechanism, 3061. Unloading cylinder, 3062. Unloading crossbar, 3063. Protective pad, 307. Base, 308. Rotating frame. Detailed Implementation

[0017] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described in this application are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0018] Example 1 Welding positioner See also Figures 2-9 A welding positioner 3 includes a base 307, a head frame column 301, a U-shaped rotating frame 308, and a tail frame column 305. A bottom frame fixture 302 is slidably connected to one end of the rotating frame 308, and a top frame fixture 304 is fixedly connected to the other end of the rotating frame 308. The bottom frame fixture 302 and the top frame fixture 304 are respectively used to clamp the bottom and top of the power cabinet, and can also clamp the side away from the rotating frame 308. The frame fixture 302 and the top frame fixture 304 form a U-shaped installation position; the head frame column 301 and the tail frame column 305 are fixedly connected to the base 307, and the head frame column 301 and the tail frame column 305 drive the rotating frame 308 to rotate; the bottom frame fixture 302 and the top frame fixture 304 are respectively provided with a flipping mechanism 303, which is used to clamp the front side of the power cabinet; the base 307 is provided with a feeding mechanism 306.

[0019] In this embodiment, a servo motor is installed inside the head frame column 301. The servo motor is connected to a planetary gear reducer via a coupling. The planetary gear reducer is connected to the rotating frame 308 via a slewing bearing. A seated bearing is installed on the tail frame column 305. The seated bearing is connected to the other end of the rotating frame 308.

[0020] See also Figures 6-8 The flipping mechanism 303 includes a support base 3035, a flipping cylinder 3031, a flipping frame 3033, and a clamping cylinder 3034. The flipping cylinder 3031 is fixed to one side of the support base 3035. The piston rod of the flipping cylinder 3031 is hinged to the first end of the flipping frame 3033. The support base 3035 is hinged to the second end of the flipping frame 3033. The first end and the second end of the flipping frame 3033 are located on the same side. The clamping cylinder 3034 is provided on the other side of the flipping frame 3033. The clamping cylinder 3034 is located at the end away from the rotating frame 308. The flipping frame 3033 and the support base 3035 are connected by a connecting rod and a rotating shaft 3032. The support base 3035 is fixedly connected to the bottom frame fixture 302 and the top frame fixture 304, respectively.

[0021] See Figure 7 When the piston rod of the tilting cylinder 3031 extends, the tilting frame 3033 and the clamping cylinder 3034 tilt and lower around the connecting rod shaft 3032; see reference Figure 8 When the piston rod of the tilting cylinder 3031 retracts, the tilting frame 3033 and the clamping cylinder 3034 tilt and open around the connecting rod shaft 3032.

[0022] See also Figure 3 , Figure 4 , Figure 9 and Figure 10 The feeding mechanism 306 includes a feeding cylinder 3061 and a feeding crossbar 3062; the feeding cylinder 3061 is hinged to the lower end of the feeding crossbar 3062, and the lower ends of the feeding crossbar 3062 are connected to the base 307 on both sides; when in the welding state, when the piston rod of the feeding cylinder 3061 retracts, the feeding crossbar 3062 lies flat (e.g., Figure 10 (As shown in the diagram) When welding is completed and material needs to be unloaded, the piston rod of the unloading cylinder 3061 extends, and the unloading crossbar 3062 flips up to push out the power cabinet for unloading; when material needs to be loaded, the piston rod of the unloading cylinder 3061 extends, and the unloading crossbar 3062 flips up to provide support for the power cabinet. The unloading crossbar 3062 is equipped with a protective pad 3063, which is made of elastic material. This protects the product surface from impact and also allows the operator to easily pull out the welded product; the elastic material includes a POM pad.

[0023] See Figure 5 The bottom frame fixture 302 and the top frame fixture 304 clamp the power cabinet on the side away from the rotating frame 308 using several corner clamping cylinders to ensure the power cabinet is clamped and reduce welding deformation.

[0024] Example 2 Power cabinet vision-guided welding workstation See also Figures 1-9 Based on embodiment 1, this embodiment includes at least one welding positioner 3, at least one welding robot 1, a laser guidance system, and an electrical cabinet platform 2. The welding robot 1 includes a welding torch system and a six-axis robotic arm. The welding torch system includes an electric welding machine, a torch cleaner, and a welding torch fixed at the end of the six-axis robotic arm. The electric welding machine supplies power and gas to the welding torch. The laser guidance system includes an industrial smart camera and a laser emitter, and the laser guidance system is fixed to one side of the welding torch. The electrical cabinet platform 2 integrates the control system of the welding workstation, including the control of the welding robot 1, the welding torch system, the laser guidance system, and the positioner.

[0025] See Figure 1 The welding positioner 3 and the welding robot 1 are in the same number. When the first welding positioner 3 is working, the second welding positioner 3 is manually loaded. The two welding robots 1 weld the power cabinet on the first welding positioner 3 at the same time. After welding is completed, the welding robot 1 welds the power cabinet on the second welding positioner 3. The first welding positioner 3 pushes the power cabinet out through the unloading mechanism 306, and then manually loads it. This cycle is repeated to achieve uninterrupted welding. The two welding positioners 3 work in turn without interruption.

[0026] Furthermore, the number of the welding positioner 3 and the welding robot 1 includes, but is not limited to, two, and the specific number can be gradually increased according to production needs.

[0027] Furthermore, the multiple welding positioners 3 and the multiple welding robots 1 can be controlled individually by multiple electrical cabinet platforms 2, or they can be collectively controlled by a single electrical cabinet platform 2.

[0028] In this embodiment, the welding robot 1 can scan and correct the weld seam during the welding process, thereby ensuring the quality of the weld seam.

[0029] Example 3 Visual-guided welding method for power cabinets A visually guided welding method for power cabinets includes the following steps: S1 Clamping Process: When using the welding workstation, the various components of the power cabinet need to be assembled and then pushed into the welding positioner 3. The bottom frame fixture 302 slides along the guide rail of the rotating frame 308 and presses the assembled power cabinet top and bottom together to ensure the length dimension of the power cabinet. Then, the piston rod of the flipping cylinder 3031 in the flipping mechanism 303 extends, and the flipping frame 3033 and the clamping cylinder 3034 flip down around the connecting rod shaft 3032. The piston rod of the clamping cylinder 3034 retracts and clamps the power cabinet on the side away from the rotating frame. At the same time, the other corner clamping cylinders clamp the power cabinet on the side away from the rotating frame 308. The small fins on the power cabinet are fixedly connected to the corresponding size position of the small fins by magnetic adsorption. The magnetic adsorption fixation can compensate for the position that is inconvenient to be fixed by the corner clamping cylinder. S2 rotation process: The head frame column 301 drives the planetary gear reducer through the servo motor. The small gear connected to the end of the planetary gear reducer transmits power to the slewing bearing. The slewing bearing drives the rotating frame 308 to rotate, and at the same time drives the clamped power cabinet to rotate to the angle suitable for welding robot 1 to weld. S3 Welding Process: The welding positioner 3 inputs the angle adjustment completion signal to the electrical cabinet platform 2. The electrical cabinet platform 2 inputs a welding signal to the welding robot 1. The laser emitter illuminates the weld seam, forming a breakpoint. The industrial intelligent camera identifies the breakpoint coordinates, fits the weld seam trajectory, and transmits the data to the electrical cabinet platform 2. Based on the fitted weld seam position, the electrical cabinet platform 2 sends a welding command to the welding robot 1. The welding robot 1 performs welding according to the command. After welding is completed, the industrial intelligent camera inputs a welding completion signal to the electrical cabinet platform 2. The electrical cabinet platform 2 inputs a stop welding signal to the welding robot 1. After detecting that the welding robot 1 has stopped welding, the industrial intelligent camera inputs a reset signal to the welding robot 1. S4 cycle process: Repeat S2 and S3 multiple times until the entire power cabinet is welded; S5 unloading process: All cylinders on the tooling are reversing and released, the bottom frame tooling 302 retracts, and the unloading cylinder 3061 on the base 307 of the welding positioner 3 drives the unloading crossbar 3062 to flip up, pushing out the power cabinet.

Claims

1. A method of visually guided welding of an electrical cabinet, characterized by: The invention includes a visually guided welding workstation for power cabinets, wherein the welding workstation includes a welding positioner, at least one welding robot, a laser guidance system, and a power cabinet platform. The welding robot includes a welding torch system and a six-axis robotic arm. The welding torch system includes an electric welding machine, a torch cleaner, and a welding torch fixed at the end of the six-axis robotic arm. The electric welding machine supplies power and gas to the welding torch. The laser guidance system includes an industrial smart camera and a laser emitter, and the laser guidance system is fixed to one side of the welding torch. The electrical cabinet platform integrates the control system of the welding workstation, including the control of the welding robot, the welding torch system, the laser guidance system, and the positioner; The welding positioner includes a base, a head frame column, a U-shaped rotating frame, and a tail frame column. A bottom frame fixture is slidably connected to one end of the rotating frame, and a top frame fixture is fixedly connected to the other end. The bottom and top frame fixtures are used to clamp the bottom and top of the power cabinet, respectively, and can also clamp the side away from the rotating frame. The rotating frame, bottom frame fixture, and top frame fixture form a U-shaped installation position. The head frame column and tail frame column are fixedly connected to the base, and drive the rotating frame to rotate. The bottom and top frame fixtures are each equipped with a flipping mechanism, which is used to clamp the front side of the power cabinet. The base is equipped with a feeding mechanism. The flipping mechanism includes a support base, a flipping cylinder, a flipping frame, and a clamping cylinder. The flipping cylinder is fixed to one side of the support base. The piston rod of the flipping cylinder is hinged to the first end of the flipping frame. The support base is hinged to the second end of the flipping frame. The first end and the second end of the flipping frame are located on the same side. A clamping cylinder is provided on the other side of the flipping frame. The clamping cylinder is located at the end away from the rotating frame. The flipping frame and the support base are connected by a connecting rod and a rotating shaft. The support base is fixedly connected to the bottom frame fixture and the top frame fixture, respectively. When the piston rod of the tilting cylinder extends, the tilting frame and the clamping cylinder tilt and lower around the connecting rod shaft to fix the power cabinet; when the piston rod of the tilting cylinder retracts, the tilting frame and the clamping cylinder tilt and open around the connecting rod shaft to release the power cabinet. The feeding mechanism includes a feeding cylinder and a feeding crossbar; the feeding cylinder is hinged to the middle of the lower end of the feeding crossbar, and the two sides of the lower end of the feeding crossbar are connected to the base; the bottom frame fixture and the top frame fixture clamp the side of the power cabinet away from the rotating frame through a number of corner clamping cylinders. When welding is completed and material needs to be unloaded, the piston rod of the unloading cylinder extends and the unloading crossbar flips up to push the power cabinet out for unloading; when material needs to be loaded, the piston rod of the unloading cylinder extends and the unloading crossbar flips up to provide support for the power cabinet. The method includes the following steps: S1 clamping process: After the various components of the power cabinet are assembled, they are pushed into the welding positioner. The bottom frame fixture is moved to press the top and bottom of the assembled power cabinet to ensure the length dimension of the power cabinet. Then, the piston rod of the flipping cylinder in the flipping mechanism extends to clamp the power cabinet on the side away from the rotating frame. At the same time, several corner clamping cylinders on the bottom frame fixture and the top frame fixture clamp the power cabinet on the side away from the rotating frame. The small fins on the power cabinet are fixed to the corresponding size position by magnetic adsorption. S2 Rotation Process: The head frame column is driven by a servo motor to drive a planetary gear reducer. The end of the planetary gear reducer is connected to a small gear to transmit power to the slewing bearing. The slewing bearing drives the rotating frame to rotate, and at the same time drives the clamped power cabinet to rotate to an angle suitable for welding by the welding robot. S3 Welding Process: The welding positioner inputs an angle adjustment completion signal to the electrical cabinet platform. The electrical cabinet platform inputs a welding signal to the welding robot. The laser emitter of the welding robot illuminates the weld seam, forming a breakpoint. The industrial intelligent camera identifies the breakpoint coordinates, fits the weld seam trajectory, and transmits the data to the electrical cabinet platform. The electrical cabinet platform sends a welding command to the welding robot based on the fitted weld seam position. The welding robot performs welding according to the command. After welding is completed, the industrial intelligent camera inputs a welding completion signal to the electrical cabinet platform. The electrical cabinet platform inputs a stop welding signal to the welding robot. After detecting that the welding robot has stopped welding, the industrial intelligent camera inputs a reset signal to the welding robot. S4 cycle process: Repeat S2 and S3 multiple times until the entire power cabinet is welded; S5 unloading process: All cylinders on the tooling are reversing and released, the bottom frame tooling retracts, and the unloading crossbar is flipped up by the unloading cylinder on the welding positioner base to push out the power cabinet.

2. The visually guided welding method for power cabinets according to claim 1, characterized in that: The head frame column is equipped with a servo motor, which is connected to a planetary gear reducer via a coupling. The planetary gear reducer is connected to the rotating frame via a slewing bearing. The tail frame column is equipped with a seated bearing, which is connected to the other end of the rotating frame.

3. The visually guided welding method for power cabinets according to claim 1, characterized in that: The feeding crossbar is equipped with a protective pad.

4. The visually guided welding method for power cabinets according to claim 1, characterized in that: The number of welding positioners and welding robots is two.

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