A welding process production system having multiple welding methods

Abstract

The application provides a welding process production system with multiple welding modes, and belongs to the field of steel coil galvanizing processing, and comprises a rack, a welding trolley and a PLC control device; a mounting bracket and a laser welding device are mounted on the welding head; two photoelectric induction switches are mounted side by side on the mounting bracket; after the PLC control device obtains workpiece signals sensed by the two photoelectric induction switches respectively, the PLC control device controls the laser welding device to weld the weld joint between the two workpieces on the welding machine table; after the PLC control device obtains that any one photoelectric induction switch does not sense a workpiece signal, the laser welding device is controlled to stop running. The application realizes the welding of equal-thickness plates and unequal-thickness plates, and also realizes the welding of unequal-width plates, effectively solves the problem of thick-specification broken welding, and the problem that unequal-width plate welding cannot be automatically operated, thereby providing effective protection for the speed increase and yield increase of the production line.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of steel coil galvanizing processing, and particularly relates to a welding process production system with multiple welding modes. BACKGROUND

[0002] A welding machine refers to an electric appliance for providing a power source with certain characteristics for welding. Welding is widely used in various industrial fields, such as steel structure processing, steel equipment manufacturing, and container manufacturing, due to its advantages of flexibility, simplicity, convenience, firmness, and reliability, and even the same strength as the base material after welding.

[0003] In order to meet the needs of on-site welding and improve welding efficiency, some welding processes use automatic welding robots. For example, application No. CN201610409061.2 discloses an intelligent welding robot device, which includes a welding manipulator, a universal workpiece rack, a CCD camera, and a control unit. The welding manipulator, the universal workpiece rack, and the CCD camera are electrically connected to the control unit. The control unit is located beside the welding manipulator. The universal workpiece rack is located directly below the welding manipulator. The CCD camera is located on the upper part of the welding manipulator. The control unit includes a host computer and a PLC controller. The PLC controller controls the actions of the welding manipulator and the universal workpiece rack in real time. During the welding process, the workpiece is fixedly installed on the universal workpiece rack. The welding manipulator performs welding operations on the workpiece. The CCD camera takes photos of the workpiece in real time during the welding process and transmits the photos to the host computer. The host computer analyzes and judges the photo information. If the welding quality is qualified, the host computer transmits a qualified signal to the PLC controller. The PLC controller controls the welding manipulator and the universal workpiece rack to stop moving, completes the welding of the workpiece, and enters the welding process of the next workpiece.

[0004] It can be seen that the prior art realizes automatic welding by combining a robot with a welding device, which greatly improves the efficiency compared with manual operation. However, in actual welding operation, two workpieces with inconsistent widths are welded. At this time, due to the inconsistent widths of the two workpieces, it is difficult to effectively find the starting welding position and match the ending welding position, which affects the operation of welding automation. Moreover, starting welding at the starting position and terminating welding at the ending position cannot be achieved, which causes the welding seam quality to be unable to meet the welding process requirements and the welding seam quality to be unstable. SUMMARY

[0005] The present application provides a welding process production system with multiple welding modes, which can realize laser welding and also perform hot galvanizing operations, effectively solve the problem of thick gauge strip breakage, and provide equipment support for increasing production speed and yield.

[0006] The system comprises a rack, a welding trolley and a PLC control device; the rack is provided with a welding machine table, and the welding trolley is provided with a welding head; a left support is installed on one side of the welding machine table, and a right support is installed on the other side of the welding machine table;

[0007] The welding head is located above the welding machine table; a mounting support and a laser welding device are installed on the welding head; the laser welding device comprises resistance welding and laser welding; the PLC control device is provided with a resistance welding and laser welding switch;

[0008] The mounting support is provided with two photoelectric sensors installed side by side; a spacing is arranged between the two photoelectric sensors; when welding is performed, the position between the two photoelectric sensors is the welding seam position between the two workpieces;

[0009] The PLC control device is connected with the photoelectric sensors and the laser welding device; after the PLC control device obtains the workpiece signals sensed by the two photoelectric sensors, the PLC control device controls the laser welding device to weld the welding seam between the two workpieces on the welding machine table; after the PLC control device obtains the workpiece signal not sensed by any one of the photoelectric sensors, the PLC control device controls the laser welding device to stop running.

[0010] It is further explained that the rack is further provided with a lifting and rolling support, and the lifting and rolling support is arranged above the welding machine table;

[0011] The bottom end of the lifting and rolling support is provided with a rolling roller, the lifting and rolling support is connected with a lifting driving mechanism, the PLC control device is connected with the lifting driving mechanism, the lifting and rolling support is driven to lift, and the rolling roller is controlled to roll the welding seam between the two workpieces.

[0012] It is further explained that the mounting support is provided with a support plate, two through holes are formed in the support plate, and a stainless steel screw sleeve is connected to the through hole position of the support plate; the photoelectric sensor is fixedly installed in the stainless steel screw sleeve, the output end of the photoelectric sensor passes through the through hole, and a protective cover is arranged outside the stainless steel screw sleeve; the protective cover is fixedly connected to the support plate;

[0013] One side of the support plate is connected with a mounting plate, a mounting hole is formed in the mounting plate, and the mounting plate is mounted to the upper mounting support through the mounting hole and the bolt.

[0014] It is further explained that the welding trolley is provided with a support seat; the welding trolley is provided with a walking wheel, the walking wheel is connected with a servo motor, the PLC control device is electrically connected with the servo motor, and the servo motor is controlled to run;

[0015] The welding machine head is provided with a head mounting stand, a plurality of vertical strip holes are formed in the head mounting stand, a support frame body is fixedly connected to the vertical strip holes through bolts, a horizontal strip hole is connected to the top end of the support frame body, and the support frame body is installed on the support seat through the horizontal strip hole;

[0016] The bottom end of the head mounting stand is fixedly connected with a U-shaped mounting plate, an arc groove is formed in the U-shaped mounting plate, and the laser welding device is installed on the U-shaped mounting plate in cooperation with the arc groove through bolts.

[0017] It should be further explained that the left support is provided with an upper left clamping plate and a lower left clamping plate, and the upper left clamping plate and the lower left clamping plate clamp and fix one workpiece on one side of the welding machine table;

[0018] The right support is provided with an upper right clamping plate and a lower right clamping plate, and the upper right clamping plate and the lower right clamping plate clamp and fix another workpiece on the other side of the welding machine table.

[0019] It should be further explained that the PLC control device comprises a man-machine interaction interface;

[0020] The man-machine interaction interface comprises an automatic operation interface, a manual operation interface, a parameter configuration interface, an alarm interface and a welding trend display interface.

[0021] It should be further explained that the PLC control device further comprises a timing module;

[0022] The parameter configuration interface is configured to configure time length information of delaying starting the laser welding device after two photoelectric induction switches respectively sense workpiece signals;

[0023] The parameter configuration interface is further configured to configure time length information of delaying closing the laser welding device after any one photoelectric induction switch does not sense a workpiece signal;

[0024] The parameter configuration interface is further configured to configure time length information of starting the laser welding device and opening the electromagnetic valves of the protective gas and the compressed gas;

[0025] The timing module performs timing according to the time length information configured by the parameter configuration interface, and sends a time signal after the timing reaches the time length.

[0026] It should be further explained that the man-machine interaction interface is provided with a water-cooled machine power switch control button, a laser power switch control button, a compressed air valve switch control button, a protective gas valve switch control button, a jogging laser welding power setting button and a welding current adjusting knob.

[0027] Further need explanation, the man-machine interface is also used to display welding data information, workpiece number, left support side plate thickness, right support side plate thickness, laser welding device light delay time, laser welding device light off delay time, laser output power information and laser welding device moving speed information.

[0028] Further need explanation, the PLC control device is also used to read welding trolley running speed through 0-10V analog signal, and after receiving trolley moving speed feedback, based on formula: laser welding power=trolley moving speed*proportion coefficient, calculate matching laser welding power.

[0029] From the above technical scheme, the present application has the following advantages:

[0030] The welding procedure production system with multiple welding methods provided by the present application has two photoelectric sensors installed side by side on the mounting bracket, and after the two photoelectric sensors sense the plate, the welding process is started by setting a delay time, meeting the welding process requirements. Based on process testing, for plates below 5mm, a reasonable uniform welding speed is selected, and a uniform start light delay time and end light delay time are set, and the delay time is fine-tuned to ensure full welding of the two plates. For thicker plates, the process package can be called to change the debugged delay time, reduce the welding speed to ensure welding quality, ensure that the welding process meets the welding process requirements, and improve the stability of the welding process.

[0031] The present application can collect welding information, facilitate user review, and effectively improve welding efficiency. It can also efficiently collect, store and process welding data, and use multi-dimensional space to describe the entire welding process. It improves the quality and efficiency of workpiece welding, discovers abnormalities in the workpiece welding process in a timely manner and provides early warning to improve welding process management level and efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0032] In order to more clearly illustrate the technical solutions of the present application, the following will briefly introduce the drawings needed to be used in the description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0033] Fig. 1 The welding procedure production system with multiple welding methods is shown in the figure.

[0034] Fig. 2 The welding head is shown in the figure.

[0035] Fig. 3 The mounting bracket is shown in the figure.

[0036] Fig. 4 An embodiment of a welding process production system with various welding methods is illustrated.

[0037] Fig. 5 An embodiment of a rolling method of the system is illustrated. DETAILED DESCRIPTION

[0038] The welding process production system with various welding methods according to the present invention is to solve the problem of unstable welding of unequal thickness plates, and the problem of unstable welding of unequal width plates. The welding process production system according to the present invention will more fully describe various embodiments of the present disclosure. The present disclosure can have various embodiments, and adjustments and changes can be made therein. However, it should be understood that there is no intention to limit various embodiments of the present disclosure to the specific embodiments disclosed herein, but the present disclosure should be understood to encompass all adjustments, equivalents, and / or alternatives falling within the spirit and scope of various embodiments of the present disclosure.

[0039] The term "include" or "may include" used in the welding process production system according to the present invention indicates the presence of the disclosed function, operation, or element, and does not limit the addition of one or more functions, operations, or elements. In addition, as used in various embodiments of the present disclosure, the term "include", "have", and their cognates are merely intended to denote a specific characteristic, number, step, operation, element, component, or combination of the foregoing, and should not be understood as first excluding the presence or addition of one or more other characteristics, numbers, steps, operations, elements, components, or combinations of the foregoing, or the possibility of one or more characteristics, numbers, steps, operations, elements, components, or combinations of the foregoing. Exemplarily, in the welding process production system according to the present invention, the expression "or" or "at least one of A or / and B" includes any combination or all combinations of the listed words. For example, the expression "A or B" or "at least one of A or / and B" can include A, can include B, or can include both A and B. It should be noted that if a description connects one constituent element to another constituent element, the first constituent element can be directly connected to the second constituent element, and a third constituent element can be "connected" between the first constituent element and the second constituent element. Conversely, when one constituent element is "directly connected" to another constituent element, it can be understood that there is no third constituent element between the first constituent element and the second constituent element.

[0040] It should be noted that the term "user" used in various embodiments of the present disclosure can indicate a person using a welding machine, a computer and related equipment. In the implementation of the function of the welding process production system with multiple welding modes, the present application is based on technologies including sensors, special artificial intelligence chips, cloud computing, distributed storage, big data processing technology, operation / interaction system, mechatronics, PLC software program, etc. Object-oriented programming languages such as Java, Smalltalk, C++, and conventional procedural programming languages such as "C" language or similar programming languages can also be used. In this way, by establishing the welding process program and parameter setting model of the numerical control welding machine tool, the real-time interactive mapping of the rack 1 and the welding trolley is realized by using sensor monitoring, data transmission and other technologies, and then the welding process on the workpiece on the rack 1 can be performed based on the welding trolley, the welding of equal-thickness plates and unequal-thickness plates can be realized, and the welding of unequal-width plates can also be realized. It can effectively solve the problem of thick specification broken belt and the problem of unequal-width plate welding that cannot be automatically operated, thereby providing effective protection for increasing production speed and yield of the production line.

[0041] Of course, in order to realize the function of the welding process production system with multiple welding modes, the PLC control device 22 involved in the present application has a device capable of automatically performing numerical calculation and / or information processing according to pre-set or stored instructions. The hardware thereof includes but is not limited to microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), digital signal processors (DSPs), embedded devices, etc. The terminal machine can also include network devices and / or user devices. Among them, the PLC control device 22 includes, but is not limited to, a single network server, a server group composed of multiple network servers, or a cloud composed of a large number of hosts or network servers based on cloud computing.

[0042] The network in which the PLC control device 22 is located includes but is not limited to the Internet, a wide area network, a metropolitan area network, a local area network, a virtual private network (VPN), etc.

[0043] The welding process production system with multiple welding modes of the present application will be described in detail below. Figs. 1 to 4 The welding process production system with multiple welding modes of the present application can be applied to the welding process of a hot dip galvanizing production line, or the welding process of ordinary carbon steel, or the welding process of some other related materials. It can match and analyze the welding parameter change trend, dynamically adjust the welding parameters, and meet the welding process requirements.

[0044] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative effort belong to the scope of protection of the present application.

[0045] Please refer to Figs. 1 to 5 As shown in the schematic diagram in the embodiment, the welding process production system with multiple welding modes comprises a rack 1, a welding trolley and a PLC control device 22. The welding trolley can be a movable trolley installed inside a factory building, and the trolley has a gantry that can realize horizontal movement and lifting. The lifting and horizontal movement can be driven by a motor. The welding trolley can be connected with the PLC control device 22, so as to realize automatic control based on the PLC control device 22 and meet the needs of automatic welding. The welding trolley can also be manually controlled by a field controller.

[0046] The rack 1 in the embodiment can be multiple. The rack 1 is used to fix and install workpieces to be welded. Specifically, a welding machine table is arranged on the rack 1, a welding head is arranged on the welding trolley, and the welding head is located above the welding machine table. A left support 2 is installed on one side of the welding machine table, and a right support 3 is installed on the other side of the welding machine table.

[0047] In order to fix the workpieces, in the embodiment, the left support 2 is provided with an upper left clamping plate 4 and a lower left clamping plate 5, and the upper left clamping plate 4 and the lower left clamping plate 5 clamp and fix one workpiece on one side of the welding machine table. The right support 3 is provided with an upper right clamping plate 6 and a lower right clamping plate 7, and the upper right clamping plate 6 and the lower right clamping plate 7 clamp and fix another workpiece on the other side of the welding machine table.

[0048] The clamping operation of the upper left clamping plate 4 and the lower left clamping plate 5 and the upper right clamping plate 6 and the lower right clamping plate 7 can be manually operated by a user, or a clamping motor can be arranged to be automatically controlled by the PLC control device 22. A limit stopper or a position sensor can be arranged to make the PLC control device 22 know the clamping-to-position information of the workpieces.

[0049] The welding head of the embodiment is provided with a mounting bracket and a laser welding device 8. The mounting manner of the laser welding device 8 on the welding trolley can be that a supporting seat is arranged on the welding trolley. The welding trolley is provided with traveling wheels, the traveling wheels are connected with a servo motor, a PLC control device 22 is electrically connected with the servo motor to control the operation of the servo motor. The welding head is provided with a head mounting vertical plate 9, a plurality of vertical slot holes 10 are arranged on the head mounting vertical plate 9, a supporting frame body 11 is fixedly connected with the vertical slot holes 10 through bolts, a horizontal slot hole 12 is connected with the top end of the supporting frame body 11, and the supporting frame body 11 is mounted on the supporting seat through the horizontal slot hole. The bottom end of the head mounting vertical plate 9 is fixedly connected with a U-shaped mounting plate 13, an arc groove is arranged on the U-shaped mounting plate 13, the laser welding device 8 is matched with the arc groove through bolts and is mounted on the U-shaped mounting plate 13.

[0050] In this way, the vertical slot holes 10 can realize vertical position adjustment, the horizontal slot holes can realize front-back adjustment in the horizontal direction, and the arc groove can realize adjustment of the welding angle of the laser welding device 8. The adjustment modes are various, can meet various adjustment needs and also meet the welding process needs.

[0051] In order to meet various welding process needs, the laser welding device 8 includes resistance welding and laser welding. The PLC control device 22 is provided with a resistance welding and laser welding switch. A user can set the current welding mode through the resistance welding and laser welding switch according to needs, which can be resistance welding or laser welding.

[0052] In an example embodiment, in order to meet the welding needs of workpieces with different widths, two photoelectric sensing switches 21 are mounted side by side on the mounting bracket. The specific mounting manner can be that a supporting plate 14 is arranged on the mounting bracket, two through holes are arranged on the supporting plate 14, and stainless steel screw sleeves 15 are connected with the positions of the through holes of the supporting plate 14. The photoelectric sensing switches 21 are fixedly installed in the stainless steel screw sleeves 15, the output ends of the photoelectric sensing switches 21 pass through the through holes, and protective covers 16 are arranged outside the stainless steel screw sleeves 15. The protective covers 16 are fixedly connected with the supporting plate 14. One side of the supporting plate 14 is connected with a mounting plate 17, mounting holes 18 are arranged on the mounting plate 17, and the mounting plate 17 is mounted on the mounting bracket through the mounting holes and bolts. The two photoelectric sensing switches 21 can face the weld, and a spacing is arranged between the two photoelectric sensing switches 21. When welding is performed, the position between the two photoelectric sensing switches 21 is the position of the weld between the two workpieces.

[0053] It can be understood that the two photoelectric sensing switches 21 only start the welding process when they can sense the workpiece at the same time. If the width of the workpiece or the plate is inconsistent, one photoelectric sensing switch 21 can sense the workpiece or the plate, and the other photoelectric sensing switch 21 cannot sense the workpiece or the plate. With the movement of the welding trolley, the other photoelectric sensing switch 21 can sense the workpiece or the plate. At this time, the position of the laser welding device 8 can be considered to be at the starting position of the weld, and the welding operation can be performed.

[0054] As an embodiment of the present application, the PLC control device 22 is connected with the photoelectric sensing switch 21 and the laser welding device 8 respectively. After the PLC control device 22 obtains the workpiece signals sensed by the two photoelectric sensing switches 21 respectively, the PLC control device 22 controls the laser welding device 8 to weld the weld between the two workpieces on the welding machine. After the PLC control device 22 obtains the workpiece signal not sensed by any one of the photoelectric sensing switches 21, the PLC control device 22 controls the laser welding device 8 to stop running.

[0055] According to the embodiment of the present application, according to the mechanical structure requirement of the welding workpiece on site, without affecting the welding operation, a high-power laser welding device 8 can also be installed. The welding trolley has front and rear, up and down, and rotating movement functions, which facilitates wide-range adjustment of the welding position. The fine adjustment of the light spot position is automatically adjusted by the control system of the laser welding device 8. The left support 2 and the right support 3 realize the clamping and positioning of the workpiece, ensure that the welding process meets the process requirement, can realize the requirement that the butt joint gap of the cut plate is ≤0.1mm, and realize that the light spot of the laser welding device 8 is in the middle of the weld.

[0056] As an embodiment of the present application, due to the lifting of the clamped plate on site, the laser welding device 8 needs to be lifted. Combined with the laser welding process, a 250mm lengthened long-focus high-power laser welding head can be customized. In the case of ensuring the welding effect without affecting the normal operation of the system, the laser welding device 8 is lifted. The welding process production system with multiple welding modes of the present application can ensure that the butt joint gap of the cut plate on site is ≤0.1mm, the straightness of the plate after butt joint is ≤0.1mm, and the up and down misalignment height of the two plates after butt joint is ≤1mm.

[0057] Further, the rack 1 is also provided with a lifting and rolling support, and the lifting and rolling support is arranged above the welding machine. The bottom end of the lifting and rolling support is provided with a rolling roller 19, and the lifting and rolling support is connected with a lifting driving mechanism. The PLC control device 22 is connected with the lifting driving mechanism to drive the lifting and rolling support to lift and further control the rolling roller 19 to roll the weld between the two workpieces. It can be seen that the rolling roller 19 can also roll the welding workpiece before welding. The uneven thickness plate is rolled before welding to ensure flatness, and does not affect the overlay welding in the welding process.

[0058] In this way, the laser welding process requirements can be combined with how to realize the welding of equal thickness plates and unequal thickness plates. Due to the different thicknesses of the coils in different batches, there will be unequal thickness plates when switching. At the same time, the plate material exists upward warping, in order to ensure the welding gap and consistency, the welding seam is flattened by pre-rolling through the rolling roller 19 before welding.

[0059] It should be noted that the photoelectric induction switch 21 of the embodiment can accurately sense the position of the plate material and the position of the welding seam. It can also be tested by the on-site induction switch before welding. Compared with the ordinary photoelectric opposite switch in the prior art, the present application has a diffuse reflection phenomenon, which will cause the light to be emitted in advance when reflected on the plate clamping plate. In view of this situation, two photoelectric induction switches 21 are provided to achieve accurate sensing of the plate material.

[0060] According to the process requirements, the PLC control device 22 can identify the position of the laser welding device 8 and control the output of the laser welding device 8. Of course, the laser welding device 8 of the present application is also connected with a welding machine, a gas protection device and related equipment to meet the needs of on-site welding.

[0061] As an embodiment of the present application, the length of the welding plate can be identified to avoid laser welding omission. Before starting welding: the laser welding device 8 passes above the plate material, and the two photoelectric induction switches 21 simultaneously sense the length of the plate on both sides to allow welding to be performed. When starting welding, the laser welding can accurately irradiate on the plate material. In the embodiment, when the laser welding device 8 leaves above the plate material, any one of the two photoelectric induction switches 21 does not sense the plate material, and the welding stops.

[0062] In the embodiment, after identifying the length of the plate, the laser welding device 8 is accurately aligned with the welding seam to make the welding seam fully welded on both sides. Of course, appropriate welding parameters can also be set in combination with the plate material, thickness, and different laser welding penetration and speed. The distance between the two photoelectric induction switches 21 can be adjusted according to the actual needs of the welding seam. After the two photoelectric induction switches 21 sense the plate material, the welding process is started by setting a delay time to meet the welding process requirements. In this way, based on the process test, the plate material below 5mm selects a reasonable uniform welding speed, sets a uniform start light delay time and end light delay time, and adjusts the delay time to ensure that the plate material on both sides is fully welded. For higher thickness plate materials, the delay time can be changed by calling the process package to reduce the welding speed to ensure the welding quality.

[0063] In this way, the photoelectric sensing switch 21 avoids the interference of the diffuse reflection of the laser. The problem of the diffuse reflection of the laser into the photoelectric sensing switch 21 during the welding process is avoided or reduced, the diffuse reflection interference is effectively avoided by arranging the stainless steel sleeve 15, and the position is symmetrical.

[0064] According to the embodiment of the application, the PLC control device 22 comprises a man-machine interface and a timing module; the man-machine interface comprises an automatic operation interface, a manual operation interface, a parameter configuration interface, an alarm interface, and a welding trend display interface.

[0065] The parameter configuration interface is configured to configure the time length information of the delay start of the laser welding device 8 after the two photoelectric sensing switches 21 respectively sense the workpiece signals; is further configured to configure the time length information of the delay closing of the laser welding device 8 after any one of the photoelectric sensing switches 21 does not sense the workpiece signal; and is further configured to configure the time length information of the opening of the laser after the electromagnetic valve of the laser welding device 8 and the protection gas and the compressed gas are opened.

[0066] The timing module can time according to the time length information configured by the parameter configuration interface, and send a time signal after timing reaches the time length. The timing module is equivalent to timing the system, and triggering the subsequent process after reaching the time length.

[0067] Optionally, the man-machine interface is provided with a water-cooled machine power switch control button, a laser power switch control button, a compressed air valve switch control button, a protection gas valve switch control button, a jogging laser welding power setting button, and a welding current adjusting knob. Of course, other related buttons can also be provided according to actual needs.

[0068] In an exemplary embodiment, the system can monitor and analyze real-time data through Ethernet, can collect waveform files, and can monitor the system running state in real time. Resistance welding and laser welding switching can also be realized, two sets of welding modes are independently operated, have double welding functions of resistance welding and laser welding, and meet the production needs. Moreover, the man-machine interface has an automatic interface, a manual interface, a parameter interface, an alarm interface, and a trend interface. The automatic interface is an interface for monitoring the running state when the automatic operation is performed (when the conditions are met, the green indicator light changes from dark to bright, ensuring the safety of the on-site operator and the equipment processing). The automatic welding start condition relationship is “and”, and after all the conditions are met, the electromagnetic valve of the protection gas and the compressed gas is opened and the laser is opened after a delay, and the light welding is performed according to the set power.

[0069] The conditions in the embodiment can include but are not limited to the following modes:

[0070] The welding carriage is in the initial position, and welding can be performed. A welding method has been selected. The automatic welding power is > 300 W. The operation table automatic / manual knob is switched to the automatic position. The laser welding device 8 is ready, and a signal from the laser Ready signal. Two photoelectric sensors 21 simultaneously detect the plate material, and the timing to the light-off delay time is started. The system has no alarm. Of course, the alarm conditions include: safety relay (emergency stop button), laser head control card alarm, laser alarm, water cooler alarm. If any of the alarms are triggered, the start condition is not met. The compressed air pressure is normal, and the condition is met. The shielding gas pressure is normal, and the condition is met.

[0071] For the automatic welding stop condition, if any of the following conditions is triggered, the welding will be stopped immediately. The material detection is not detected, that is, any of the two photoelectric sensors 21 cannot detect the plate material. The automatic / manual knob is switched to another position, and the welding is immediately stopped. There is an alarm, and the alarm conditions include: safety relay (emergency stop button), laser head control card alarm, laser alarm, water cooler alarm. If any of the alarms is triggered, the welding is immediately stopped. The signal from the welding carriage is not allowed to weld, the condition of 200 cm / min ≤ car speed ≤ 500 cm / min is not met, or the signal is lost, and the welding is immediately stopped.

[0072] According to the embodiment of the present application, when performing the point operation welding, the following conditions need to be met: the automatic / manual knob is switched to the manual position, and welding can be performed. The laser is ready. The system has no alarm. All the above conditions are met, and the point operation light button is pressed to point the welding.

[0073] In this embodiment, the PLC control device 22 can also configure the recipe parameters. The recipe parameters are the screen for setting the automatic operation parameters, and all the parameters during operation are set here. The recipe includes: data record name, recipe number, input side plate thickness, output side plate thickness, light-off delay time, light-off delay time, laser power, welding carriage speed, etc. The recipe can store 300. When a new recipe is created, a new button can be created based on the operation interface, all parameters are input, and saved. If the recipe does not need to be deleted, select the delete button, if you want to change the data record name, select the rename button. After selecting the recipe, the data is written, and this recipe will be called, and the data will take effect in the PLC control device 22. Of course, if you do not want to use the parameters in the recipe, you can select the recipe power button, switch to the manual power with a yellow background, and input the power in the lower input box. The automatic operation will automatically call the manually input power output.

[0074] In the embodiment, the PLC control device 22 also realizes automatic power adjustment, and automatically adjusts the laser power according to the welding trolley speed.

[0075] In this way, the welding information can be summarized, and the user can conveniently check the welding information, and the welding efficiency is effectively improved. The welding data can be efficiently collected, stored and processed, and the entire welding process is described by using a multi-dimensional space. The quality and efficiency of workpiece welding are improved, and abnormalities in the workpiece welding process are discovered in time and pre-warned, so that the welding process management level and efficiency are improved.

[0076] The units and algorithm steps of each example described in the embodiments disclosed in the welding process production system with multiple welding modes can be realized by electronic hardware, computer software or a combination of both. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in the above description. Whether the functions are executed in hardware or software depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0077] It should be understood that the disclosed system, device and method can be implemented in other ways in the welding process production system with multiple welding modes. For example, the device embodiment described above is only schematic, for example, the division of the units is only a logical function division, and actual implementation can have another division manner, for example, a plurality of units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between the units shown or discussed can be indirect coupling or communication connection through some interfaces, devices or units, and can also be electrical, mechanical or other forms of connection.

[0078] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the application. One skilled in the relevant art will recognize, however, that the

[0079] The foregoing description of the disclosed embodiments enables a person skilled in the art to make or use the application. Modifications of these embodiments will occur to persons of skill in the art, and, although aspects of this application are recited specifically in this disclosure, they are not to be construed as prohibiting the application of these general principles to other embodiments taught or suggested by the content of this disclosure. Accordingly, the application is not to be limited to only those embodiments shown and described herein but is intended to encompass any and all embodiments falling within the scope of the claims.

Claims

1. A welding process production system with multiple welding methods, characterized in that, include: The machine includes a frame, a welding crane, and a PLC control unit. The frame is equipped with a welding machine table, the welding crane is equipped with a welding head, a left support is installed on one side of the welding machine table, and a right support is installed on the other side of the welding machine table. The welding head is located above the welding machine table; the welding head is equipped with a mounting bracket and a laser welding device; the laser welding device includes resistance welding and laser welding; the PLC control device is equipped with a resistance welding and laser welding switching switch. Two photoelectric sensors are mounted side by side on the mounting bracket, with a gap between them. During welding, the position between the two photoelectric sensors indicates the weld seam position between the two workpieces. The PLC control device is connected to the photoelectric sensor switch and the laser welding device respectively. After the PLC control device receives the workpiece signal from the two photoelectric sensors, it controls the laser welding device to weld the weld between the two workpieces on the welding machine. After the PLC control device receives the workpiece signal from either photoelectric sensor switch, it controls the laser welding device to stop running. The frame is also equipped with a lifting and rolling support, which is located above the welding machine. The bottom of the lifting and rolling support is equipped with a rolling roller. The lifting and rolling support is connected to a lifting drive mechanism. The PLC control device is connected to the lifting drive mechanism to drive the lifting and rolling support to rise and fall, thereby controlling the rolling roller to roll the weld between the two workpieces. The mounting bracket is equipped with a support plate with two through holes. Stainless steel threaded sleeves are connected to the through holes of the support plate. The photoelectric sensor switch is fixedly installed inside the stainless steel threaded sleeve, and the output end of the photoelectric sensor switch passes through the through holes. A protective cover is provided on the outside of the stainless steel threaded sleeve. The protective cover is fixedly connected to the support plate. A mounting plate is connected to one side of the support plate. The mounting plate has mounting holes and is installed onto the mounting bracket through the mounting holes and bolts.

2. The welding process production system with multiple welding methods according to claim 1, characterized in that, The welding crane is equipped with a support base; the welding crane is equipped with traveling wheels, the traveling wheels are connected to servo motors, and the PLC control device is electrically connected to the servo motors to control the operation of the servo motors. The welding head is equipped with a head mounting plate, which has multiple vertical slots. A support frame is fixedly connected to the vertical slots by bolts. A horizontal slot is connected to the top of the support frame, and the support frame is installed onto the support base through the horizontal slot. A U-shaped mounting plate is fixedly connected to the bottom of the machine head mounting plate. The U-shaped mounting plate has an arc groove. The laser welding device is installed on the U-shaped mounting plate by bolts fitting into the arc groove.

3. The welding process production system with multiple welding methods according to claim 1, characterized in that, The left bracket is equipped with an upper left clamping plate and a lower left clamping plate, which clamp and fix one of the workpieces to one side of the welding machine. The right bracket is equipped with an upper right clamping plate and a lower right clamping plate, which clamp and fix another workpiece to the other side of the welding machine.

4. The welding process production system with multiple welding methods according to claim 1, characterized in that, The PLC control device includes: a human-machine interface; The human-machine interface includes: automatic operation interface, manual operation interface, parameter configuration interface, alarm interface, and welding trend display interface.

5. The welding process production system with multiple welding methods according to claim 4, characterized in that, The PLC control unit also includes: a timing module; The parameter configuration interface is used to configure the duration of the delay before starting the laser welding device after the two photoelectric induction switches have received workpiece signals from the two photoelectric induction switches respectively. It is also used to configure the duration of the delay before the laser welding device is turned off after any photoelectric sensor switch fails to detect a workpiece signal; It is also used to configure the delay time information for starting the laser after the solenoid valves for the protective gas and compressed gas are opened after starting the laser welding device; The timing module starts timing based on the duration information configured in the parameter configuration interface, and sends out an end signal after the timing reaches the specified duration.

6. The welding process production system with multiple welding methods according to claim 4, characterized in that, The human-machine interface is equipped with power switch control buttons for the water chiller, laser, compressed air valve, and protective gas valve, as well as a jog laser welding power setting button and a welding current adjustment knob.

7. The welding process production system with multiple welding methods according to claim 4, characterized in that, The human-machine interface is also used to display welding data information, workpiece number, thickness of plate on the left support side, thickness of plate on the right support side, laser welding device light emission delay time, laser welding device light off delay time, laser output power information, and laser welding device moving speed information.

8. The welding process production system with multiple welding methods according to claim 3, characterized in that, The PLC control unit is also used to read the operating speed of the welding trolley through a 0-10V analog signal, and after receiving feedback on the trolley's moving speed, it calculates and matches the laser welding power based on the formula: laser welding power = trolley moving speed × proportional coefficient.

Images