Laser wire filling beam self-weight state automatic assembly welding pretreatment system and method

Abstract

The application belongs to the technical field of automatic assembly welding pretreatment, and provides an automatic assembly welding pretreatment system and method based on laser wire filling crossbeam self-weight state. The application can realize automatic assembly and feeding and discharging of crossbeam assembly, flexible use of multiple vehicle types, and integration of welding and polishing of crossbeam composed rigid clamps, and realizes data shortest time closed loop detection by using welding cluster control system and welding simulation, so as to achieve automatic assembly, visual recognition filling, quality process control, free adjustment and repair data closed loop, and automatic welding quality of crossbeam assembly.

Description

Technical Field

[0001] This invention belongs to the field of pre-treatment technology for welding assembly, and relates to an automatic pre-treatment system and method for welding assembly based on the self-weight state of a laser-filled wire crossbeam. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] The crossbeams in bogie vehicle manufacturing have complex structures, involve a large amount of welding, and are difficult to control in terms of quality. Assembly processes mostly rely on manual assembly, with high-level manual welding pretreatment to ensure the quality of the root welds. Robotic automated welding is then used to complete the production process. However, the accuracy of manual assembly is difficult to guarantee, and pretreatment requires high levels of human skill. For mass production, long-term deformation data statistical optimization is necessary. Ineffective processes such as adjustment and marking occupy a significant amount of workspace, making full automation impossible.

[0004] According to the inventor, existing domestic and international methods generally use manual assembly or more complex semi-automatic assembly combined with MAG welding. At the same time, the back assembly is limited by tooling and cannot achieve the original welding pre-treatment. In addition, the MAG weld points need to be further cleaned after welding, resulting in a long manufacturing cycle and high manufacturing costs due to repeated adjustments. Summary of the Invention

[0005] To address the aforementioned problems, this invention proposes an automatic pre-treatment system and method for welding crossbeams under their own weight, based on laser-filled wire. This invention enables automated assembly and loading / unloading of crossbeams, flexible use across multiple vehicle models, and an integrated welding and grinding device for rigid clamps of the crossbeams. Simultaneously, it utilizes a welding cluster control system and welding simulation to achieve closed-loop detection of data in the shortest possible time, thus achieving automated assembly, visual recognition filling, quality process control, and maintenance-free data closed-loop, thereby automating the assembly and welding quality of crossbeams.

[0006] According to some embodiments, the present invention adopts the following technical solution:

[0007] An automatic pretreatment method for welding laser-loaded crossbeams under their own weight includes the following steps:

[0008] The welding sequence and process parameters were determined by simulating the welding sequence under the self-weight of the crossbeam.

[0009] Welding and assembly are performed to achieve a bonding connection of the workpiece under gravity.

[0010] Determine the finished position and dimensions of each workpiece, and adjust the dimensions and position of each workpiece accordingly;

[0011] Root welding of laser filler wire welding at the connection positions of each workpiece is performed to achieve preliminary rigid fixation of all welding positions;

[0012] The welding process quality is monitored. When welding quality problems occur, abnormal data is introduced into the simulation step for analysis and iteration, and feedback on the quality problems is provided.

[0013] Perform beam inspection and welding effect inspection, and optimize the process parameters in the simulation steps based on the inspection results.

[0014] As an alternative implementation method, during the process of determining the welding process sequence and process parameters by simulating the welding sequence under the self-weight state of the crossbeam, each workpiece is dropped according to the principle of weight from large to small, combined with the principle of length from long to short based on the length of the workpiece.

[0015] As an alternative implementation, welding robots are used for welding assembly, with the robot's manipulator or gripping device used to hold each workpiece.

[0016] As an alternative implementation method, the specific process of determining the completed position and size of each workpiece and adjusting the size and position of each workpiece includes scanning the baseline according to the outer contour of each workpiece, and at the same time confirming the fit ratio of the interface to be welded. If the fit ratio is less than the set value, it is judged as unqualified and the material needs to be replaced.

[0017] As an alternative implementation method, the specific process of performing root welding of laser filler wire welding at each workpiece connection position includes: using a clamping device to clamp the workpiece, using a robot to grab the laser filler wire power supply, and completing the root welding of laser filler wire welding at each position.

[0018] As an alternative implementation method, the specific process of introducing abnormal data into the simulation step for analysis and iteration includes: when the cumulative error of the assembled component exceeds the upper limit, the data is considered abnormal. When the data is abnormal, the calibrated dimensions are input into the simulation calculation model to complete the calculation of welding deformation and stress, and the welding sequence and heat input are readjusted locally.

[0019] As an alternative implementation method, a laser model comparison machine is used to inspect the crossbeam, and ultrasonic or laser scanning is used to inspect the welding effect.

[0020] As an alternative implementation method, the specific process of optimizing the process parameters in the simulation step based on the test results includes: scanning and confirming the data of the assembled and fixed parts; importing the assembly difference data into the simulation calculation; fine-tuning the process that exceeds the tolerance after the calculation is completed; recalculating the welding deformation; predicting the quality changes that will be caused by the assembly difference; and finally determining the welding sequence and parameters.

[0021] An automatic pre-treatment system for welding laser-filled wire crossbeams under their own weight includes:

[0022] The simulation module is configured to determine the welding process sequence and process parameters by simulating the welding sequence under the self-weight state of the crossbeam.

[0023] Automated welding equipment is used for welding assembly, completing the bonding connection of workpieces under gravity; performing root welding of laser filler wire welding at the connection positions of each workpiece to achieve preliminary rigid fixation of all welding positions;

[0024] Laser inspection mechanism is used to determine the finished position and size of each workpiece in order to adjust the size and position of each workpiece;

[0025] The monitoring device is used to monitor the quality of the welding process. When welding quality problems occur, abnormal data is introduced into the simulation step for analysis and iteration, and feedback is provided on the quality problems.

[0026] The testing device is used to inspect the crossbeams and the welding effect, and to optimize the process parameters in the simulation steps based on the test results.

[0027] As an alternative implementation, the automated welding apparatus includes:

[0028] A pallet used to support beams or materials;

[0029] AGV carts used for movement;

[0030] Robotic systems used for gripping workpieces or materials;

[0031] Fixtures used for positioning or clamping workpieces;

[0032] Laser-assisted wire-filling welding robot used to perform welding.

[0033] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0034] This invention can realize the automated assembly of crossbeam components and solve the inherent problem of non-penetration of conventional MAG welding joints, thus providing a method for the integrated automated assembly and pretreatment of crossbeam components.

[0035] This invention achieves integrated workpiece welding pretreatment and data closed-loop operation, realizing a simulation, inspection, automated assembly, and on-the-go integrated welding operation mode. This improves the pretreatment welding process.

[0036] This invention can reduce the working area of ​​crossbeam welding, which is conducive to the agility of product quality optimization, facilitates the automation of welding operations, and improves the production capacity, efficiency and benefits of multi-model compatible production. At the same time, it improves the welding quality of crossbeams, homogenizes welding stress, and prepares the technical groundwork for the subsequent elimination of the annealing process.

[0037] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0038] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0039] Figure 1 This is a schematic diagram of the pretreatment process for automated beam assembly welding;

[0040] Figure 2 This is a schematic diagram of the various devices in the automated beam welding pretreatment system;

[0041] Figure 3 This is a schematic diagram of the laser filler wire welding method.

[0042] Among them, 1. Crossbeam material pallet; 2. AGV transport vehicle; 3. Small and medium-sized material pallet; 4. Grabbing robot system; 5. Accompanying fixture positioning tooling; 6. Laser wire filling welding robot; 7. Laser measuring component; 8. One-axis reversing device; 9. Crossbeam assembly integrated tooling. Detailed Implementation

[0043] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0044] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0045] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0046] Example 1

[0047] A laser-filled wire crossbeam self-weight state welding pretreatment method is proposed to realize the automated assembly and loading / unloading of crossbeams, flexible use in multiple vehicle models, and an integrated welding and grinding device for rigid clamps of crossbeams. At the same time, the welding cluster control system and welding simulation are used to realize the shortest time closed-loop detection of data, achieving automated assembly, visual recognition filling, quality process control, and maintenance-free data closed loop, thus achieving automation and confidence in crossbeam assembly and welding quality.

[0048] To solve the following problems:

[0049] 1) Automated assembly of bogie crossbeams, free-state welding preprocessing, agile data recovery and optimization;

[0050] 2) Solve the problem of numerous manual processes and large floor space occupied by ineffective processes in the production line;

[0051] 3) To achieve flexibility in rigid fixtures composed of crossbeams, thus enabling the crossbeams and side beams to be universally applicable in automated operating systems;

[0052] 4) Achieve the goal of fully automating and eliminating the need for adjustment in the beam operation process, and realize the closed loop of beam composition data.

[0053] The following is a description of a specific embodiment, including the following steps:

[0054] Step 1: Determine the welding sequence and process parameters by simulating the welding sequence under the self-weight of the crossbeam. In this process, the components (or workpieces) are dropped into the beam according to the principle of weight from large to small, combined with the principle of length from large to small for each component.

[0055] Step 2: Automated welding and assembly are completed using an offline robot programming system, achieving the bonding and connection of the workpiece under gravity.

[0056] Step 3: Use laser positioning scanning to determine the completed position and size of each component, adjust the size and position of each component with the fixture, and calibrate the robot arm data;

[0057] During this process, the baseline is scanned according to the outer contour of each workpiece, and the matching ratio of the interface to be welded is confirmed. If the fitting rate is less than 70%, it is considered unqualified and the material needs to be replaced.

[0058] Step 4: Using a transfer and return tool for reinforcement, a robot is used to grab the laser filler wire power supply to complete the root welding of laser filler wire welding at each position, achieving preliminary rigid fixation of all welding positions;

[0059] Step 5: After the crossbeam is automatically assembled, the welding process quality is monitored by an AGV. When welding quality problems occur, abnormal data is transmitted to the simulation for analysis and iteration, and the quality problems are fed back to the system.

[0060] When the cumulative error of the assembled components exceeds the upper limit, such as a total length deviation of more than 3mm or a width deviation of more than 2mm, the dimensions after scanning calibration are input into the simulation calculation model to complete the calculation of welding deformation and stress, and the welding sequence and heat input are readjusted locally.

[0061] Step Six: After welding, the workpiece undergoes automatic beam inspection using a laser model comparison machine. The welded sections are then inspected for surface stress and strain using ultrasonic or laser scanning. In this embodiment, an existing portal-type laser 3D scanning system can be used to achieve rapid, non-stop quality inspection of the workpiece, comparing all outer contours.

[0062] Based on the comparison of test results and welding simulation data, the model of the laser 3D scanning system and the simulation steps were optimized. This included: first, data scanning to confirm the assembled and fixed components; second, importing assembly difference data into the simulation calculation; third, fine-tuning the process for exceeding tolerances after calculation; fourth, calculating welding deformation; fifth, predicting quality changes caused by assembly differences; and finally, determining the welding process flow and / or parameters.

[0063] In addition, considering the influence of factors such as the placement of the workpiece, the shooting angle, and the lighting, the entire 3D model data can be obtained through scanning. Then, through relevant software, the optimal fit and comparison can be completed to check the conformity of the workpiece.

[0064] In this embodiment, the specific implementation process is carried out by a processing system, as described in the following reference. Figure 2 The production line system uses an integrated tooling 9 for transporting, welding, pre-processing, and assembling the welded beams, completing the placement of the automated welding system. AGV transport vehicles 2 transport materials from beam material trays 1 and small-part material trays 3. A gripping robot 4 completes the installation and adjustment of the positioning garment tooling 5, while an assembly gripping robot 7 performs positioning and detection, laser-detecting pre-positioned components to achieve pre-assembly of the beam components. The integrated tooling 9 for welding and pre-processing the beams completes the clamping and fixing of each component. A laser wire-filling welding robot 6 is used to complete the integrated welding and laser wire-filling operations of the beam components, such as... Figure 3 As shown;

[0065] The crossbeams are pre-treated by laser wire filling to form the front and back sides. The gripping robot system 4 is used to remove the accompanying fixture positioning tool 5 and loosen the clamping. The back of the part has a weld seam, which requires laser wire filling welding pre-treatment. The welding position is PA. The workpiece is reversed by a one-axis reversing device 8. At the same time, it can also realize different vehicle structures for the front and back sides, and realize rapid production changeover.

[0066] The integrated beam assembly tooling 9 completes the transfer of the beam components and the subsequent robotic welding;

[0067] For welding completion and process quality issues, follow-up improvements are made. Laser measurement component 7 performs pre- and post-test verification of laser detection data to further optimize welding quality.

[0068] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A pretreatment method for automatic assembly welding of laser-loaded crossbeams under their own weight, characterized in that, Includes the following steps: The welding sequence and parameters were determined by simulating the welding sequence under the self-weight of the crossbeam; welding assembly was then carried out to complete the bonding connection of the workpiece under gravity. Determine the finished position and size of each workpiece, and adjust the size and position of each workpiece. Specifically, scan the baseline according to the outer contour of each workpiece, and at the same time confirm the matching ratio of the welding connection surfaces. If the fitting rate is less than the set value, it is judged as unqualified and the material needs to be replaced. Root welding of laser filler wire welding at the connection positions of each workpiece is performed to achieve preliminary rigid fixation of all welding positions; The welding process quality is monitored. When welding quality problems occur, abnormal data is introduced into the simulation step for analysis and iteration, and feedback on the quality problems is provided. Specifically, when the cumulative error of the assembled parts exceeds the upper limit, the data is considered abnormal. When the data is abnormal, the calibrated dimensions are input into the simulation calculation model to complete the calculation of welding deformation and stress, and the welding sequence and heat input are readjusted locally. Perform beam inspection and welding effect inspection, and optimize the process parameters in the simulation steps based on the inspection results; In the process of determining the welding sequence and process parameters by simulating the welding sequence under the self-weight of the beam, the workpieces are dropped into the beams according to the principle of decreasing weight, combined with the principle of decreasing workpiece length.

2. The pretreatment method for automatic assembly welding of a laser-loaded crossbeam based on its self-weight state as described in claim 1, characterized in that, Welding robots are used for welding assembly, with the robot's robotic arm or clamping device used to hold each workpiece.

3. The pretreatment method for automatic assembly welding of a laser-loaded crossbeam based on its self-weight state as described in claim 1, characterized in that, The specific process of root welding for laser wire filler welding at each workpiece connection position includes: using a clamping device to clamp the workpiece, using a robot to grab the laser wire filler power source, and completing the root welding of laser wire filler welding at each position.

4. The pretreatment method for automatic assembly welding of a laser-loaded crossbeam based on its self-weight state as described in claim 1, characterized in that, A laser model comparison machine is used to inspect the crossbeams, and ultrasonic or laser scanning is used to inspect the welding effect.

5. The pretreatment method for automatic assembly welding of a laser-loaded crossbeam based on its self-weight state as described in claim 1, characterized in that, Based on the test results, the specific process for optimizing the process parameters in the simulation steps includes: scanning and confirming the data of the assembled and fixed parts; importing the assembly difference data into the simulation calculation; fine-tuning the process that exceeds the tolerance after the calculation; recalculating the welding deformation; predicting the quality changes that will be caused by the assembly difference; and finally determining the welding sequence and parameters.

6. A pre-treatment system for automatic assembly welding of a laser-filled wire crossbeam under its own weight, employing the pre-treatment method for automatic assembly welding of a laser-filled wire crossbeam under its own weight as described in any one of claims 1-5, characterized in that, include: The simulation module is configured to determine the welding process sequence and process parameters by simulating the welding sequence under the self-weight state of the crossbeam. Automated welding equipment is used for welding assembly, completing the bonding connection of workpieces under gravity; performing root welding of laser filler wire welding at the connection positions of each workpiece to achieve preliminary rigid fixation of all welding positions; Laser inspection mechanism is used to determine the finished position and size of each workpiece in order to adjust the size and position of each workpiece; The monitoring device is used to monitor the quality of the welding process. When welding quality problems occur, abnormal data is introduced into the simulation step for analysis and iteration, and feedback is provided on the quality problems. The testing device is used to inspect the crossbeams and the welding effect, and to optimize the process parameters in the simulation steps based on the test results.

7. The automatic pre-treatment system for welding a laser-filled wire crossbeam under its own weight, as described in claim 6, is characterized in that... The automated welding device includes: A pallet used to support beams or materials; AGV carts used for movement; Robotic systems used for gripping workpieces or materials; Fixtures used for positioning or clamping workpieces; Laser-assisted wire-filling welding robot used to perform welding.

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