A stud welding gun and its positioning method

Abstract

The present invention relates to a processing technology for stud welding, and it relates to a welding torch for a stud and a positioning method thereof, including a welding torch body and a tip gun head of the welding torch body. The gun head includes two sleeves, a spring, and a roller. The inner cylinder has a cavity for the stud to be inserted. The outer cylinder is sleeved outside the inner cylinder to form a movable channel. The inner spring is placed in the movable channel. A notch is formed on the outer peripheral wall of the inner cylinder, and the notch extends and communicates with the cavity. The roller is inserted into the notch, and a part of the outer peripheral wall of the roller extends into the cavity of the inner cylinder. When the stud is inserted into the cavity, the stud presses the roller, and the roller moves along the path of the notch while compressing the spring until the clamping part of the stud abuts against the roller. A positioning unit is installed in the welding torch body to remind the operator of the positioning welding position. The present invention has stable clamping of the stud, is convenient for detaching the stud, can achieve automatic positioning and guide the operator to drive the welding torch to the positioning point.

Description

Technical Field

[0001] The present invention relates to a processing technology for stud welding, and more specifically, it relates to a welding torch for studs and its positioning method. Background Art

[0002] Welding refers to a process of permanently joining metal or non-metal materials together by methods such as melting or plastic deformation. Welding is an important basic process in manufacturing and is widely used in industries such as aerospace, shipbuilding, automotive, construction, and machinery. An arc welding torch is a welding tool that uses the high temperature generated by an arc to melt the welding electrode and the base material, thereby forming a weld seam. The arc welding torch is the most widely used type of welding torch at present.

[0003] For example, the publication number CN218080893U discloses a new type of drawn-arc stud welding torch, which solves the technical problems of low accuracy of the telescopic position and telescopic distance of the gun core of the traditional stud welding torch.

[0004] The publication number CN115041791A discloses a marine drawn-arc adaptive stud welding torch. For this marine drawn-arc adaptive stud welding torch, a guiding mechanism is provided relative to the mechanism of the traditional welding torch. When the stud is lifted and pressed down, the movement is stable. The linear bearing is provided and there will be no eccentricity problem, and the frictional resistance is small. The welding torch can work stably. Through the extrusion force between the ball and the moving part, the moving part moves up and down. At the same time, it is convenient to adjust the lifting height of the welding torch, which can ensure the smooth progress of welding.

[0005] The publication number CN202667890U discloses a drawn-arc stud welding torch. When the positive and negative electrodes of the welding power supply are energized, the electromagnet attracts the armature, causing the stud to leave the mother plate by a short distance, and an arc is drawn between the two. After that, the electromagnet is powered off, and under the action of the spring, the stud impacts the mother plate, and the two are welded together instantaneously under high temperature, which has the advantages of good welding effect and simple operation.

[0006] There are two problems in the use of the above-mentioned welding torches in the prior art. The first is that when the chuck for clamping the stud clamps the stud, after the stud is welded, it is not easy for the welding torch to disengage from the stud, resulting in a stuck situation. The second point is that when the welding torch welds the stud, it cannot achieve the positioning of the position where the stud is to be welded. That is, if the studs are to be welded in an array or other shapes, it cannot be achieved. To achieve this purpose, it is necessary to lay out marks on the connecting parts to be welded first, and this method makes the efficiency of the overall welding project very low. Summary of the Invention

[0007] Aiming at the deficiencies of the prior art, the purpose of the present invention is to provide a welding torch for studs and its positioning method that can stably clamp the stud, is convenient to disengage from the stud, can achieve automatic positioning and guide the operator to drive the welding torch to the positioning point.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A stud welding gun, comprising a welding gun body, the end of the welding gun body is provided with a gun head for coaxially sleeving a stud, the gun head includes two cylinders sleeved inside and outside, a spring, and a roller. The inner cylinder has a cavity for the stud to be inserted. The outer cylinder is sleeved outside the inner cylinder to form a movable channel.

[0010] The inner spring is placed in the movable channel and sleeved outside the inner cylinder. A notch is formed on the outer peripheral wall of the inner cylinder, and the notch extends and communicates with the cavity of the inner cylinder. The roller is inserted into the notch, and a part of the outer peripheral wall of the roller extends into the cavity of the inner cylinder.

[0011] The outer peripheral wall of the inner cylinder has a stepped portion, and a limiting ring is also sleeved outside the inner cylinder. The roller presses against one end face of the limiting ring.

[0012] One end of the spring abuts against the stepped portion, and the other end abuts against the other side of the limiting ring. When the stud is inserted into the cavity, the stud presses against the roller, and the roller moves along the path of the notch while pressing the spring to contract until the clamping portion of the stud abuts against the roller.

[0013] A positioning unit is installed inside the welding gun body to remind the operator of the welding position.

[0014] The present invention is further provided that: two notches are symmetrically arranged, the notches are parabolic, there are two rollers, and they are respectively placed in the notches. The notches have a section for the rollers to move along, and the section is inclined.

[0015] The present invention is further provided that: the positioning unit includes a MEMS sensor, a motor, and an optical locator, so that the MEMS sensor detects the position and attitude of the welding gun, the motor reminds the operator to adjust the position of the welding gun, and then the optical locator is used to indicate the direction in which the stud is to move.

[0016] A positioning method for stud welding includes the following steps:

[0017] S1. The operator arbitrarily selects a first positioning point for welding, clamps the stud with the welding gun and welds it in place, triggers the MEMS sensor to record the current position as the first reference positioning point, and activates the position control function;

[0018] S2. During the welding process at the first positioning point, the operator adjusts the position of the welding gun according to the real-time data provided by the MEMS sensor, so that the stud is perpendicular to the welding position and welded in place.

[0019] S3. When welding the next stud, the optical locator provides guidance on the welding direction, indicating the direction in which the operator should move the welding gun. The MEMS sensor real-time detects the distance the welding gun moves and compares it with the first reference positioning point. When the set position is reached, the MEMS sensor notifies the operator to perform the welding task, which becomes the second reference positioning point, and the MEMS sensor records the current position as the new reference positioning point;

[0020] S4. Repeat the steps of S1 - S3 above to complete the welding of the stud array on the connector. The present invention is further configured as follows: In step S3, if the MEMS sensor detects that the welding gun deviates from the predetermined path or approaches the target position, a vibration is generated by the motor to alert the operator.

[0021] The present invention is further configured as follows: The frequency of the motor vibration is output according to a preset mode. When deviating from the predetermined path, the motor vibrates continuously; when approaching the target, the motor vibrates intermittently.

[0022] The present invention is further configured as follows: The positioning unit is also coupled with a remote control unit and a proximal control unit.

[0023] The remote control unit includes a communication module and a remote execution module. The remote execution module is the mobile phone end, which is coupled with the MEMS sensor through the communication module, and outputs the positions of the studs on the connector through the mobile phone.

[0024] The proximal control unit includes a wire coupled with the MEMS sensor and a control panel placed on the welding machine case, and outputs the positions of the studs on the connector through the control panel.

[0025] Compared with the deficiencies of the prior art, the beneficial effects of the present invention are as follows:

[0026] By improving the chuck design and the ergonomic design of the welding gun, the grip feeling and weight balance of the handheld welding equipment are optimized, the labor burden of the operator is reduced, the comfort and controllability during the welding process are improved, the operation fatigue is reduced, and it helps to improve the production efficiency and welding quality.

[0027] The intelligent positioning technology and the auxiliary guiding device are introduced to help the operator accurately locate the welding position and the stud, improving the accuracy and stability of the welding. The operator can more precisely control the movement of the welding gun, reduce errors and corrections, thereby improving the welding quality and consistency.

[0028] It has an adaptive function, can adapt to the welding of different types and specifications of studs, improves the adaptability and flexibility of the equipment, reduces the operation burden and error rate of the operator.

[0029] When the stud welding position deviates from the predetermined path, the operator is prompted to adjust the position of the welding gun through vibration; when the welding is completed or a fault occurs, the operator is reminded to take corresponding measures through sound or optical signals, improving the operator's alertness and reaction speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a schematic structural diagram of the present invention;

[0031] Figure 2 is a schematic diagram of the interior of the gun head of the present invention;

[0032] Figure 3 is a schematic flow diagram of the present invention.

[0033] Welding gun body 1, gun head 2, outer cylinder 21, inner cylinder 22, spring 23, roller 24, stud 3, notch 30, limit ring 4, step portion 5, motor 6, optical locator 7. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] Refer to Figures 1 to 3 to further illustrate the embodiments of the present invention.

[0035] This embodiment specifically includes: a welding gun body 1, and the end of the welding gun body 1 is provided with a gun head 2 for coaxially sleeving a stud 3. The gun head 2 includes two coaxially nested cylinders, a spring 23, and a roller 24.

[0036] The inner cylinder 22 has an inner cavity for accommodating the stud 3, and the outer cylinder 21 is sleeved outside the inner cylinder 22 to form a movable channel therewith. A notch 30 is provided on the outer peripheral wall of the inner cylinder 22, and the notch 30 communicates with the inner cavity.

[0037] The inner spring 23 is placed in the movable channel, and the roller 24 is inserted into the notch 30. A part of the outer peripheral wall of the roller 24 extends into the inner cavity of the inner cylinder 22. The roller 24 is inserted into the notch 30 to support the movement of the stud 3. The spring 23 is placed in the movable channel and supports the movement of the roller 24 by compression. Among them, two symmetrically distributed notches 30 are in a parabolic shape. This design can ensure the stable insertion of the stud 3 and its movement along a predetermined path. One roller 24 is placed in each notch 30, and there are two rollers 24 in total. They precisely match the shape of the notch 30, enabling the roller 24 to move freely along the inclined section. The design of the roller 24 moving in the notch 30 is to ensure sufficient space for the stud 3 when it is inserted into the inner cavity. At the same time, after the stud 3 is completely inserted, the roller 24 will squeeze it to ensure its fixation in the correct position. This design not only ensures the stability of the stud 3 but also ensures the accuracy of the welding process. Through this design, automatic alignment and fixation of the stud 3 can be achieved during the welding process, thereby improving the welding efficiency and quality.

[0038] In addition, a stepped portion 5 is provided on the outer peripheral wall of the inner cylinder 22, and a limiting ring 4 is sleeved outside the inner cylinder 22. The roller shaft 24 presses against one end face of the limiting ring 4. One end of the spring 23 abuts against the stepped portion 5, and the other end abuts against the other side of the limiting ring 4. Specifically, the roller shaft 24 is designed to press against one end face of the limiting ring 4, and one end of the spring 23 contacts the stepped portion 5, and the other end contacts the other side of the limiting ring 4. This design ensures that when the stud 3 is inserted into the inner cavity, the stud 3 applies pressure to the roller shaft 24, causing the roller shaft 24 to move along the opening path of the notch 30 and compressing the spring 23 until the clamping portion of the stud 3 contacts the roller shaft 24, thereby realizing the stable fixation of the stud 3.

[0039] The positioning unit in the welding torch body 1 is designed to assist the operator in accurately positioning the welding position and ensure the accuracy and stability of the welding process. The positioning unit includes a MEMS sensor, a motor 6, and an optical locator 7. The MEMS sensor is responsible for detecting the position and posture of the welding torch. The motor 6 reminds the operator to adjust the position of the welding torch through vibration, and the optical locator 7 indicates the direction in which the stud 3 should move. The optical locator 7 is a laser projector that can emit visible red laser light.

[0040] The positioning unit is also coupled to a remote control unit and a proximal control unit. The remote control unit includes a communication module and a remote execution module. The remote execution module is installed on the mobile phone side. By coupling with the communication module and the MEMS sensor, it can output the positions of the stud 3 on the connector on the mobile phone. This enables the operator to remotely monitor the welding process and make necessary adjustments.

[0041] On the other hand, the proximal control unit includes a wire coupled to the MEMS sensor and a control panel installed on the welding machine case. Through the control panel, the operator can directly output the position information of the stud 3 on the connector and perform real-time monitoring and control of the welding process.

[0042] A positioning method for stud 3 welding includes the following steps.

[0043] The first step is to select the first positioning point and trigger the MEMS sensor to record:

[0044] The operator arbitrarily selects the first positioning point for welding, clamps the stud 3 with the welding torch and welds it in place, triggers the MEMS sensor to record the current position as the first reference positioning point, which is, and activates the position control function.

[0045] MEMS sensor trigger: Trigger condition = The operator selects the first positioning point for welding and triggers the condition.

[0046] Step 2: Adjust the position of the welding gun according to the MEMS sensor data, where the control input: = Output of the PID controller.

[0047] During the welding process at the first positioning point, the operator adjusts the position of the welding gun according to the real-time data provided by the MEMS sensor. The real-time data provided by the MEMS sensor comes from a remote mobile phone or a proximal control panel, so that the stud 3 is perpendicular to the welding position and welded and fixed.

[0048] Step 3: Guide the next welding direction and compare positions:

[0049] When welding the next stud 3, the optical locator 7 provides guidance on the welding direction, indicating to the operator which direction to move the welding gun. The MEMS sensor detects the distance the welding gun moves in real time and compares it with the first reference positioning point. When the set position is reached, the MEMS sensor notifies the operator to perform the welding task, which becomes the second reference positioning point, and the MEMS sensor records the current position as the new reference positioning point;

[0050] If the MEMS sensor detects that the welding gun deviates from the predetermined path or approaches the target position, the motor 6 generates vibrations to remind the operator. The vibration frequency of the motor 6 is output according to a preset mode. When deviating from the predetermined path, the motor 6 vibrates continuously. When approaching the target, the motor 6 vibrates intermittently.

[0051] Among them, the optical locator 7 guides: Optical locator 7 guidance = Direction light guided by the optical locator 7

[0052] Distance comparison: Distance comparison = Current position

[0053] Vibration of motor 6: Vibration of motor 6 = Vibration mode determined according to the MEMS detection result.

[0054] To more effectively remind the operator, a breathing light is set on the optical locator 7. The color and blinking mode of the breathing light can be used as a visual indicator during the welding process to provide intuitive feedback.

[0055] Breathing light status = Status determined according to the distance comparison result and the guidance of the optical locator 7.

[0056] Normal state: The breathing light maintains a stable brightness and color, indicating that the welding process is in normal progress and the operator does not need to make additional adjustments or pay attention.

[0057] Welding position needs to be adjusted: When the MEMS sensor detects that the welding gun deviates from the predetermined path or approaches the target position, the breathing light can change color, for example, from green to yellow, and start to flash slowly. This change can attract the operator's attention and prompt them that a position adjustment is needed.

[0058] Approaching the target position: When the welding gun is about to reach the set welding position, the breathing light can change to red and flash at a faster frequency. This change tells the operator that they are approaching the target position and need to be more vigilant and cautious.

[0059] With this setting, the operator can visually understand the status and required actions during the welding process by observing the changes in the breathing light. This visual indicator can effectively improve attention and reaction speed during the welding process, thus ensuring the smooth progress and high-quality completion of the welding task.

[0060] Fourth step, repeat the steps of Step 1 - 3 to complete the arrangement welding of the stud 3 array or other patterns.

[0061] Combining the process triggered by the MEMS sensor and guided by the optical locator 7, we can integrate it into the state update step to adjust the state estimation according to the sensor information. The specific mathematical model is as follows:

[0062] We define the output of the PID controller:

[0063]

[0064] Among them, is the deviation error signal,

[0065] are the proportional, integral, and derivative gains of the PID controller,

[0066] represents the integral of the error signal e ,

[0067] represents the derivative of the error signal e ,

[0068] Secondly, we use the Kalman filter to update the state estimation ,

[0069] Prediction step:

[0070]

[0071] Update step:

[0072]

[0073] Among them, A is the state transition matrix, B is the input matrix, C is the observation matrix, Q is the process noise covariance matrix, R is the observation noise covariance matrix, P is the state covariance matrix,

[0074] and K is the Kalman gain.

[0075] The above model combines the real-time adjustment of the PID controller and the state estimation of the Kalman filter, and can be used to accurately locate the target position.

[0076] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included in the protection scope of the present invention.

Claims

1. A stud welding gun, characterized in that: It includes a welding torch body (1). At the end of the welding torch body (1), there is a gun head (2) for coaxially sleeving a stud (3). The gun head (2) includes two coaxially nested cylinders, a spring (23), and a roller (24). The inner cylinder (22) has a cavity for the stud (3) to be inserted. The outer cylinder (21) is sleeved outside the inner cylinder (22) to form a movable channel. The spring (23) is placed in the movable channel and sleeved outside the inner cylinder (22). On the outer peripheral wall of the inner cylinder (22), there is a cut (30). The cut (30) extends and communicates with the cavity of the inner cylinder (22). A roller (24) is inserted into the cut (30). A part of the outer peripheral wall of the roller (24) extends into the cavity of the inner cylinder (22). On the outer peripheral wall of the inner cylinder (22), there is a stepped portion (5). An outer limiting ring (4) is also sleeved outside the inner cylinder (22). For the outer limiting ring (4), the roller (24) presses on one end face of the outer limiting ring (4). One end of the spring (23) abuts against the stepped portion (5), and the other end abuts against the other side of the outer limiting ring (4). So when the stud (3) is inserted into the cavity, the stud (3) squeezes the roller (24). While the roller (24) moves along the opening path of the cut (30), it presses the spring (23) to contract until the clamping part of the stud (3) abuts against the roller (24). A positioning unit is installed inside the welding torch body (1) to remind the operator of the positioning welding position. Two cuts (30) are symmetrically arranged. The cuts (30) are parabolic. There are two rollers (24) which are respectively placed in the cuts (30). The cuts (30) have inclined planes for the rollers (24) to move along. The positioning unit includes a MEMS sensor, a motor (6), and an optical locator (7). The MEMS sensor senses the stud welding position and reminds the operator of the accuracy of the stud welding position through the motor (6).

2. A positioning method for stud welding, using a stud welding torch as described in claim 1, including the following steps. S1. The operator arbitrarily selects a first positioning point for welding, clamps the stud (3) with the welding torch and welds it in place, triggers the MEMS sensor to record the current position as the first reference positioning point, and activates the position control function. S2. During the welding at the first positioning point, the operator adjusts the position of the welding torch according to the real-time data provided by the MEMS sensor so that the stud (3) is perpendicular to the welding position and welded in place. S3. When welding the next stud (3), the optical locator (7) provides guidance on the welding direction, indicating the direction in which the operator should move the welding torch. The MEMS sensor real-time detects the moving distance of the welding torch and compares it with the first reference positioning point. When the set position is reached, the MEMS sensor notifies the operator to perform the welding task. This is the second reference positioning point, and the MEMS sensor records the current position as the new reference positioning point. S4. Repeat the steps of S1 - S3 to complete the array arrangement and welding of the studs (3) on the connecting piece.

3. The positioning method for stud welding according to claim 2, wherein: In step S3, if the MEMS sensor detects that the welding torch deviates from the predetermined path or approaches the target position, vibration is generated by the motor (6) to alert the operator.

4. The positioning method for stud welding according to claim 3, characterized in that: The vibration frequency of the motor (6) is output according to a preset mode. When deviating from the predetermined path, the motor (6) vibrates continuously. When approaching the target, the motor (6) vibrates intermittently.

5. A stud welding gun according to claim 1, wherein: The positioning unit is also coupled with a remote control unit and a proximal control unit. The remote control unit includes a communication module and a remote execution module. The remote execution module is the mobile phone terminal, which is coupled with the MEMS sensor through the communication module, and outputs the positions of the studs (3) on the connecting piece on the mobile phone. The proximal control unit includes a wire coupled with the MEMS sensor and a control panel placed on the welding machine case, and outputs the positions of the studs (3) on the connecting piece through the control panel.

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