A wire feeding and straightening integrated welding gun device for a humanoid welding robot

Abstract

The present invention provides a welding gun device with integrated wire feeding and straightening for a humanoid welding robot, comprising a welding gun body, a wire reel, a wire feeding mechanism assembly, a straightening mechanism assembly, and a main controller; the wire reel, straightening mechanism assembly, wire feeding mechanism assembly, and welding gun body are arranged in sequence along the wire feeding path; the straightening mechanism assembly comprises a straightening mechanism housing, a straightening driving wheel, a straightening driven wheel, a driving wheel position adjustment module, and a residual amount detection module; the driving wheel position adjustment module adjusts the position of the straightening driving wheel based on the amount of residual wire in the wire reel detected by the residual amount detection module, thereby adjusting the distance between the straightening driving wheel and the straightening driven wheel, thereby adjusting the straightening force applied to the welding wire. The device integrates a welding gun, a wire feeder, and a wire straightening mechanism into one device, and is installed at the end of the robot arm of the humanoid welding robot for use. During the welding operation, the device performs adaptive wire straightening adjustments as the amount of residual wire decreases.

Description

Technical Field

[0001] The present invention relates to the technical field of humanoid robots, and more particularly to a wire-feeding and straightening integrated welding gun device for a humanoid welding robot. Background Art

[0002] With the vigorous development of artificial intelligence technology and high-computing power digital chip technology, the research, development and application of humanoid robots and welding robot systems have received widespread attention. The characteristics of humanoid robots are extremely flexible motion control, which can meet the work requirements of complex movements, are more adaptable to complex environmental conditions, and the system hardware and software configuration is easy to adjust and replace. The welding robot system is generally composed of a welding robot arm, a welding gun wire feed mechanism, a welding power supply, a welding control center and various sensor systems. It can obtain high-quality welds through digital welding waveform control and precise robot arm trajectory motion control. Combining the outstanding characteristics of the two has resulted in a humanoid welding robot. The purpose of using a humanoid welding robot is to be able to adapt to complex working space conditions and extreme environmental conditions while achieving high-precision and high-quality welding operations.

[0003] According to a search, in existing welding robot systems, the welding wire feeder and welding gun are typically assembled separately. For example, according to the Chinese invention patent "Servo Wire Feeder for Automatic Welding Robot" (Publication No.: CN107160010A), the welding wire feeder is typically mounted with the wire feed mechanism mounted on the elbow or wrist joint of the welding robot arm, and the wire reel is placed near the base of the welding robot arm. A long welding cable runs along the welding robot arm, connecting the wire reel, wire feed mechanism, and welding gun mounted at the end of the robot arm. The wire feeder in this type of traditional welding robot has a long wire feeding distance, resulting in a complex wire feeding transmission mechanism. Furthermore, the drive motor requires a high power level, and the wire reel must hold a large amount of wire. These factors result in a bulky and heavy welding wire feeder, making it difficult to accommodate a humanoid welding robot that needs to move flexibly within a workspace.

[0004] If a humanoid welding robot uses the welding torch and wire feeder commonly used by current welding robots to perform welding operations in complex environments, the selection and layout of the welding cable connecting the welding torch and wire feeder must also be considered. The length and minimum curvature radius of this cable limit the humanoid welding robot's workspace. Furthermore, longer cables are more prone to bending and twisting during the robot's movement, increasing wire feeding resistance and making it difficult to ensure stable wire feeding. Improving wire feeding capacity requires increasing the drive power of the wire feeder, which in turn increases the weight of the wire feeder.

[0005] Therefore, there is an urgent need to invent a new type of welding gun device that is lightweight, compact, integrates wire feeding and welding gun functions, and has the ability to perform human-machine interactive control with a humanoid robot. The device can be installed at the execution end of the humanoid robot arm and can simultaneously serve as the welding gun and wire feeder of the humanoid welding robot to meet the complex space welding operation needs of the humanoid welding robot on site. Summary of the Invention

[0006] In order to overcome the shortcomings and deficiencies in the prior art, the purpose of the present invention is to provide a wire feeding and straightening integrated welding gun device for a humanoid welding robot; the device integrates a welding gun, a wire feeder and a welding wire straightening mechanism into one, and is installed at the end of the robotic arm of the humanoid welding robot for use. During the welding operation, the welding wire is adaptively straightened and adjusted as the amount of remaining welding wire decreases; it can meet the needs of the humanoid welding robot to carry out difficult welding operations and complete flexible welding movements under complex environmental conditions.

[0007] To achieve the above-mentioned object, the present invention is implemented through the following technical solutions: a wire-feeding and straightening integrated welding gun device for a humanoid welding robot, comprising a welding gun body, a wire reel, a wire feeding mechanism assembly for forwarding the welding wire, a straightening mechanism assembly for straightening the welding wire, and a main controller; the wire reel, straightening mechanism assembly, wire feeding mechanism assembly, and welding gun body are sequentially arranged along a welding wire feeding path; the main controller includes a main control chip; the main control chip is signal-connected to the welding gun body, wire feeding mechanism assembly, and straightening mechanism assembly, respectively;

[0008] The straightening mechanism assembly includes a straightening mechanism housing with a straightening inner cavity, a straightening driving wheel, a straightening driven wheel, a driving wheel position adjustment module, and a residual amount detection module for detecting the amount of remaining welding wire in the wire reel; the straightening driving wheel and the straightening driven wheel are both located in the straightening inner cavity, and the straightening driving wheel and the straightening driven wheel are staggered to form a welding wire straightening channel;

[0009] The straightening driven wheel is rotatably connected to the straightening inner cavity wall; the straightening driving wheel is rotatably arranged on the driving wheel position adjustment module, and the driving wheel position adjustment module is connected to the straightening mechanism housing to achieve position adjustment of the straightening driving wheel;

[0010] According to the remaining amount of welding wire on the wire reel detected by the residual detection module, the driving wheel position adjustment module adjusts the position of the straightening driving wheel to adjust the distance between the straightening driving wheel and the straightening driven wheel, thereby adjusting the straightening force on the welding wire; the smaller the remaining amount of welding wire on the wire reel, the smaller the distance between the straightening driving wheel and the straightening driven wheel.

[0011] Preferably, the residual detection module includes a detection mark; one end of the detection mark is connected to the driving wheel position adjustment module to adjust the position synchronously with the straightening driving wheel; the other end of the detection mark extends into the wire reel; the detection mark is connected to the high-level signal; the straightening driving wheel is connected to the GND level signal;

[0012] According to the amount of remaining wire on the wire reel detected by the residual detection module, the driving wheel position adjustment module adjusts the position of the straightening driving wheel, which means: judging the amount of remaining wire on the wire reel according to the output level signal of the detection mark:

[0013] When the detection mark outputs a GND level signal, the main controller determines that the detection mark is connected to the straightening active wheel signal through the welding wire, and the detection mark is in contact with the welding wire in the wire reel, and the active wheel position adjustment module does not adjust the straightening active wheel position;

[0014] When the detection mark outputs a high-level signal, the main controller determines that the detection mark does not contact the welding wire in the wire reel, and controls the driving wheel position adjustment module to adjust the position of the straightening driving wheel to reduce the distance between the straightening driving wheel and the straightening driven wheel.

[0015] Preferably, the driving wheel position adjustment module includes a screw-nut transmission mechanism, a straightening drive stepper motor, and a stepper motor mounting bracket; the straightening drive stepper motor is arranged on the stepper motor mounting bracket; the straightening drive stepper motor is connected to the screw-nut transmission mechanism; the straightening driving wheel is rotatably arranged on the nut structure of the screw-nut transmission mechanism; one end of the detection mark is connected to the nut structure of the screw-nut transmission mechanism;

[0016] The nut structure of the screw-nut transmission mechanism is also slidably connected to the straightening inner cavity wall through a slide rail to achieve sliding direction and position limiting.

[0017] Preferably, the main controller further comprises an adaptive welding wire straightening detection module and a straightening stepping motor control module;

[0018] The adaptive welding wire straightening detection module is connected to the GPIO function pin of the main control chip, and the adaptive welding wire straightening detection module is connected to the straightening active wheel and the detection mark in the straightening mechanism assembly to transmit a level signal for judging the remaining amount of welding wire in the wire reel; the straightening stepper motor control module is connected to the PWM function pin of the main control chip, and the straightening stepper motor control module outputs a control signal to the straightening drive stepper motor in the straightening mechanism assembly.

[0019] Preferably, there are more than two straightening driven wheels; a welding wire straightening inlet and a welding wire straightening outlet are respectively provided on both sides of the straightening mechanism housing, and the centers of the welding wire straightening inlet, the welding wire straightening outlet and the welding wire inlet of the wire feeding mechanism assembly are located on a spatial straight line tangent to the lower edges of all the straightening driven wheels.

[0020] Preferably, the wire reel frame includes a wire reel support frame, a wire reel, a damping shaft and a wire limiting mechanism; the damping shaft is installed on the wire reel support frame, and the wire reel is mounted on the damping shaft; the wire limiting mechanism is installed on the wire reel support frame, located below the wire reel, and is used to press the edge of the wire reel to prevent the welding wire from detaching. The wire limiting mechanism is provided with a pressing force on the edge of the wire reel by a torsion spring.

[0021] Preferably, it also includes a shielding gas control kit; the shielding gas control kit includes a shielding gas electromagnetic valve and a valve outlet pipe; the shielding gas electromagnetic valve is connected to an external shielding gas supply device and is installed on the wire feeding mechanism assembly; the valve outlet pipe is connected between the shielding gas electromagnetic valve and the welding gun body.

[0022] Preferably, the welding gun body includes a copper conductive nozzle, a diverter and a nozzle connecting section, a copper conductive body, a wire feed guide tube and a shielding gas joint; the copper conductive nozzle, the diverter and the nozzle connecting section and the copper conductive body are connected to each other, and the center axes are located on the same spatial straight line; the wire feed guide tube is sleeved inside the copper conductive body; the shielding gas joint is connected to the upper part of the copper conductive body, and the shielding gas joint is connected to the gas valve outlet pipe in the shielding gas control kit; the welding wire entry end of the copper conductive body has a thread and is fixed with a nut to the welding cable terminal connected to the external welding power supply.

[0023] Preferably, the wire feeding mechanism assembly includes an active wire feeding gear, a wire feeding pressing gear, a pressing gear adjusting handle, a wire feeding assembly housing, a wire guide nozzle, a wire feeding PMSM motor, a wire feeding motor mounting bracket and a wire feeding motor encoder; the active wire feeding gear is installed in the wire feeding assembly housing; the wire feeding pressing gear is connected to the pressing gear adjusting handle and is installed above the active wire feeding gear; the wire feeding pressing gear is engaged with the active wire feeding gear when there is no welding wire, and is used to press the welding wire and push the welding wire out when there is welding wire; the pressing gear adjusting handle is used to preset the pressing force on the welding wire; the welding wire inlet and the welding wire outlet of the wire feeding mechanism assembly are respectively located outside the wire feeding assembly On both sides of the shell; the meshing lines of the welding wire inlet, the welding wire outlet, the active wire feeding gear and the wire feeding pressing gear are on a straight line in space; the welding wire outlet of the wire feeding assembly shell is connected to the welding gun body; the wire guide nozzle is installed at the welding wire inlet to guide the welding wire into the wire feeding mechanism assembly; the wire feeding motor mounting bracket is installed below the wire feeding assembly shell; the wire feeding PMSM motor is fixed in the wire feeding motor mounting bracket, and the output shaft of the wire feeding PMSM motor is perpendicular to the central axis of the active wire feeding gear in space, and the wire feeding torque is transmitted through the worm gear; the wire feeding motor encoder is installed at the bottom of the wire feeding motor mounting bracket, below the wire feeding PMSM motor;

[0024] The wire feeding mechanism assembly is connected to a terminal rotating pan-tilt platform; the terminal rotating pan-tilt platform includes a pan-tilt platform motor and a pan-tilt platform bracket; the pan-tilt platform bracket is installed below the wire feeding motor mounting bracket in the wire feeding mechanism assembly, and the pan-tilt platform motor is installed in the pan-tilt platform bracket.

[0025] Preferably, the main controller further includes a CAN communication module, a protective gas valve control module, a PMSM-FOC dual drive control module and a system over-temperature and over-voltage protection module;

[0026] The CAN communication module is connected to the CAN function pin of the main control chip and communicates with the external humanoid welding robot through a CAN communication cable; the shielding gas valve control module is connected to the GPIO function pin of the main control chip, and the shielding gas valve control module outputs a control signal to the shielding gas control kit; the PMSM-FOC dual-drive control module is respectively connected to the PWM function pin, ADC function pin and TIMER function pin of the main control chip, and the PMSM-FOC dual-drive control module outputs a drive control signal to the wire feeding PMSM motor in the wire feeding mechanism assembly and the pan-tilt motor in the end rotating pan-tilt and receives encoder data from the wire feeding motor encoder in the wire feeding mechanism assembly and the pan-tilt motor in the end rotating pan-tilt; the system over-temperature and overvoltage protection module is connected to the ADC function pin of the main control chip.

[0027] The working principle of the wire feeding and straightening integrated welding gun device of the present invention is:

[0028] The main controller is connected to the external humanoid welding robot through a CAN communication cable and a power supply cable; the welding gun body is connected to the external welding power supply through a welding cable; the shielding gas control kit is connected to the external argon gas cylinder through a gas pipe; the main control chip in the main controller communicates with the external humanoid welding robot through the CAN communication module to receive work task commands; the shielding gas valve control module of the main controller outputs a control signal to control the switch of the protector solenoid valve in the shielding gas control kit, and the shielding gas is input to the shielding gas connector on the welding gun body through the gas valve outlet pipe. The shielding gas passes through the copper conductive body and is output to the environment from the diverter and the nozzle connection section. The main controller's adaptive wire straightening detection module connects to the straightening drive wheel and wire quantity detection mark in the straightening mechanism assembly. The straightening drive wheel is connected to a GND-level signal, while the wire quantity detection mark is connected to a 5V-level signal. When the wire quantity detection mark contacts the wire in the wire spool, the adaptive wire straightening detection module inputs a GND-level signal to the main control chip. When the wire quantity detection mark does not contact the wire in the wire spool, the adaptive wire straightening detection module inputs a 5V-level signal to the main control chip, indicating that the remaining wire is low and the wire is severely bent. This indicates that the straightening drive wheel in the straightening mechanism assembly needs to be pushed upward to strengthen the straightening force, causing the wire quantity detection mark to re-contact the wire in the wire spool. The straightening stepper motor control module in the main controller receives the PWM control signal output by the main control chip, driving the straightening drive stepper motor in the straightening mechanism assembly to rotate the threaded rod, which in turn drives the drive wheel slider to move the straightening drive wheel upward. The PMSM-FOC dual-drive control module in the main controller converts and amplifies the PWM drive signal from the main control chip and outputs it to the PMSM motor in the wire feeder assembly and the pan / tilt motor in the end-stage rotary pan / tilt. It collects current data from these motors for torque closed-loop control and receives encoder data from the motors for speed closed-loop control. The PMSM motor's output shaft transmits torque to the active wire feed gear via a worm gear, rotating it. The wire feed pressure gear, with its pressure set to a preset value by the pressure gear adjustment handle, is driven by the active wire feed gear, pushing the welding wire entering from the wire guide nozzle through the wire outlet on the wire feeder assembly housing and into the welding gun body. The welding wire enters the wire feed guide tube, passes through the welding gun body, and comes into contact with the copper conductive tip. Welding energy from an external welding power source is transferred to the wire through the copper conductive body and the copper conductive tip. During welding, the welding energy is transferred from the wire to the workpiece. The wire reel holder uses a damping shaft to prevent the reel from rotating and causing the wire to become scattered. A wire limiter is pressed against the side of the reel to prevent the wire from escaping during feeding. The terminal rotating platform is designed to rotate 360° under CAN communication control from an external humanoid welding robot to adjust the posture of the present invention's integrated wire feeding and straightening welding gun device for a humanoid welding robot during welding operations.

[0029] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0030] 1. The wire-feeding and straightening integrated welding gun device proposed in the present invention has the advantages of high integration, small size, compact structure and lightweight. It eliminates the need for the humanoid welding robot to connect to and carry the bulky and complex wire feeder used by conventional welding robots, which can significantly reduce the load of the humanoid welding robot and improve the operational flexibility and spatial adaptability of the humanoid robot in complex welding sites. In addition, since the wire feeding path is significantly shortened, the stability and accuracy of wire feeding are easier to ensure, and the anti-interference ability is significantly improved.

[0031] 2. The present invention proposes an adaptive straightening method for large-curvature welding wires, which can effectively solve the problem of adaptive straightening of variable-curvature welding wires. A lightweight wire-feeding and straightening integrated welding gun device must be equipped with a miniaturized wire feed reel. The smaller the wire feed reel, the greater the curvature of the wire entering the straightening wheel. The curvature of the wire bending varies with the amount of wire on the wire reel. The fewer wires, the more severe the wire bending. The present invention provides an adaptive wire straightening adjustment scheme. When the amount of remaining wire on the wire reel decreases, the wire straightening force is actively strengthened to ensure that problems such as wire jamming, wire breakage, and slipping caused by changes in the curvature of the wire bending do not occur during the welding operation.

[0032] 3. The present invention provides a complete digital wire feeding, shielding gas, straightening and welding gun posture control system, and adopts PMSM-FOC dual-drive control module to achieve faster response speed and more accurate output torque and speed control of wire feeding PMSM motor and pan / tilt motor than the existing technology, ensuring the stability of wire feeding speed and the accuracy of the posture of the present invention during welding operation, and having a system over-temperature and over-voltage protection module to ensure the safety of the present invention when used in industrial sites. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of the overall structure of the wire feeding and straightening integrated welding gun device of the present invention;

[0034] Figure 2 It is a structural schematic diagram of the straightening mechanism assembly of the wire feeding and straightening integrated welding gun device of the present invention;

[0035] Figure 3 This is a schematic diagram of the installation of the straightening mechanism assembly and the wire reel of the wire feeding and straightening integrated welding gun device of the present invention;

[0036] Figure 4 This is a schematic diagram of the wire feeding and straightening integrated welding gun device of the present invention applied to a humanoid welding robot;

[0037] Figure 5 This is a schematic diagram of the main control system of the wire feeding and straightening integrated welding gun device of the present invention. DETAILED DESCRIPTION

[0038] The present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.

[0039] Example

[0040] like Figure 1 As shown in the figure, this embodiment of a welding torch device with integrated wire feeding and straightening for a humanoid welding robot includes a shielding gas control kit 110, a welding torch body 120, a wire feeding mechanism assembly 130, a wire reel 140, a straightening mechanism assembly 150, a terminal rotary pan / tilt table 160, and a main controller 170. The main controller 170 is connected to an external humanoid welding robot via a CAN communication cable and a power supply cable, and receives work task instructions using the CAN protocol. The welding torch body 120 is connected to an external welding power source via a welding cable to transmit welding energy to the workpiece.

[0041] The shielding gas control kit 110 is connected to an external shielding gas supply (e.g., an argon cylinder) via a gas pipe to provide welding shielding gas. The shielding gas control kit 110 includes a shielding gas solenoid valve 111 and a valve outlet pipe 112. The shielding gas solenoid valve 111 is bolted to the top of the wire feeder assembly. The valve outlet pipe connects the shielding gas solenoid valve 111 to the welding torch body 120. The opening and closing of the shielding gas solenoid valve 111 determines whether shielding gas is supplied to the welding torch body 120.

[0042] The welding gun body 120 includes a copper conductive tip 121, a flow divider and nozzle connection section 122, a copper conductive body 123, a wire guide 124, and a shielding gas connector 125. The copper conductive tip 121, the flow divider and nozzle connection section 122, and the copper conductive body 123 are connected in sequence by threads, with their central axes located on the same straight line in space. The copper conductive tip 121 and the copper conductive body 123 are primarily used to transmit welding energy. The flow divider and nozzle connection section 122 is used to evenly divide the shielding gas and connect to an external shielding gas nozzle. This external shielding gas nozzle is not specified in this embodiment because various nozzle types may be used depending on the welding conditions. The wire guide 124 is inserted into the copper conductive body 123, guiding the welding wire to the copper conductive tip 121 and isolating the welding energy from the copper conductive body 123. Shielding gas connector 125 is threadedly connected to the upper portion of copper conductive body 123 and is connected to gas valve outlet pipe 112 in shielding gas control kit 110. The wire inlet end of copper conductive body 123 is threaded and secured with a nut to a welding cable terminal connected to an external welding power source.

[0043] The wire feed mechanism assembly 130 includes an active wire feed gear 131, a wire feed pressure gear 132, a pressure gear adjustment handle 133, a wire feed assembly housing 134, a wire guide nozzle 135, a wire feed PMSM motor 136, a wire feed motor mounting bracket 137, and a wire feed motor encoder 138. The active wire feed gear 131 is mounted in the center of the wire feed assembly housing 134. The wire feed pressure gear 132, coupled to the pressure gear adjustment handle 133, is mounted above the active wire feed gear 131. When no wire is present, the pressure gear 132 engages with the active wire feed gear 131. When wire is present, it compresses the wire and pushes it forward. The pressure gear adjustment handle 133 is used to preset the pressure on the wire. The wire feed assembly housing 134 has a wire inlet and a wire outlet on either side. The meshing lines between the wire inlet and the wire outlet, the active wire feed gear 131, and the wire feed pressure gear 132 are aligned in space. The wire outlet of the wire feed assembly housing 134 is threadedly connected to the copper conductive body 123 in the welding gun body 120. A wire guide nozzle 135 is threaded and fixed to the wire inlet by a nut, guiding the welding wire into the wire feed mechanism assembly 130. During wire feeding, the welding wire passes from the wire guide nozzle 135 through the wire inlet of the wire feed assembly housing 134, is pressed and pushed by the active wire feed gear 131 and the wire feed pressure gear 132, and is then fed from the wire outlet into the welding gun body 129. The wire feed motor mounting bracket 137 is mounted below the wire feed assembly housing 134. The PMSM motor 136 is secured within the mounting bracket 137. The output shaft of the PMSM motor 136 is perpendicular to the central axis of the active wire feed gear 131, transmitting the wire feeding torque via a worm gear. The wire feed motor encoder 138 is mounted at the bottom of the mounting bracket 137, below the PMSM motor 136. The wire spool bracket 140 comprises a wire spool support bracket 141, a wire spool 142, a damping shaft 143, and a wire limiting mechanism 144. The wire spool support bracket 141 is bolted to the wire feed assembly housing 134 of the wire feed mechanism assembly 130 at the wire inlet. The damping shaft 143 is mounted at the rear of the wire spool support bracket 141. The wire spool 142 is mounted on the damping shaft, which prevents the wire spool 142 from rotating. Wire retaining mechanism 144 is mounted to the rear of wire spool support frame 141, below wire spool 142. It is used to compress the edge of the spool to prevent the wire from escaping. A torsion spring provides the retaining force on the edge of wire spool 142. Wire spool 142 is typically designed for 1 kg, and the weight of the wire should not exceed 2 kg. Excessive wire can cause difficulty in feeding and damage wire spool frame 140.

[0044] The terminal rotating pan / tilt 160 includes a pan / tilt motor 161 and a pan / tilt bracket 162. The pan / tilt bracket 162 is bolted to the underside of the wire feed motor mounting bracket 137 in the wire feed mechanism assembly 130. The pan / tilt motor 161 is also bolted to the pan / tilt bracket 162. The pan / tilt motor 161 is preferably an outer rotor PMSM motor with a built-in encoder that outputs encoder signals to the main controller 170.

[0045] like Figure 2 and Figure 3 As shown, the straightening mechanism assembly 150 includes a straightening driven wheel 151, a straightening driving wheel 152, a straightening mechanism housing 153, a driving wheel position adjustment module and a margin detection module. The driving wheel position adjustment module includes a threaded rod 154, a driving wheel slider 155, a straightening drive stepper motor 157 and a stepper motor mounting bracket 158. The margin detection module includes a detection mark 156. The straightening mechanism housing 153 is provided with a straightening inner cavity; the straightening driving wheel 151 and the straightening driven wheel 152 are both located in the straightening inner cavity, and the straightening driving wheel 151 and the straightening driven wheel 152 are staggered to form a welding wire straightening channel. There are more than two straightening driven wheels 151, and in this embodiment, there are two straightening driven wheels 151; the straightening driven wheel 151 is rotatably connected to the wall of the straightening inner cavity.

[0046] The straightening mechanism housing 153 has a wire straightening inlet and outlet on either side. The centers of the wire straightening inlet, outlet, and wire inlet of the wire feed assembly housing 134 lie on a straight line tangent to the lower edges of the two straightening driven pulleys 151. The straightening mechanism housing 153 is bolted to the front of the wire reel support frame 141 of the wire reel rack 140. The straightening drive pulley 152 is connected to the drive pulley slider 155 via a connecting metal rod. The straightening drive pulley compresses the welding wire, causing it to bend away from the tangent line at the lower edges of the two straightening driven pulleys 151, thereby straightening the bent wire. A threaded rod 154 is connected to the threaded center of the drive pulley slider 155. There are two rows of driving wheel rails at the lower part of the straightening mechanism housing 153. The rotational motion of the threaded rod 154 is transmitted to the driving wheel slider 155. The driving wheel slider 155 is limited by the two rows of driving wheel rails and drives the straightening driving wheel 152 to run. The running trajectory of the straightening driving wheel 152 is perpendicular to the line connecting the centers of the two straightening driven wheels 151. The more the straightening driving wheel 152 runs upward, the stronger the straightening force on the bent welding wire is, and the welding wire with a larger degree of bending can be straightened.

[0047] A detection mark 156 is mounted above the driving wheel slider 155, pointing toward the interior of the wire spool 142 in the wire reel 140. The detection mark 156 is connected to a high-level signal; the straightening driving wheel 152 is connected to a GND-level signal. When welding wire is present in the wire spool 142, the detection mark 156 can transmit a level signal to the main controller 170 by contacting the welding wire. When the detection mark outputs a GND-level signal, the main controller determines that the detection mark is connected to the straightening driving wheel signal through the welding wire, indicating that the detection mark has contacted the welding wire in the wire reel, and the driving wheel position adjustment module does not adjust the position of the straightening driving wheel. When the detection mark outputs a high-level signal, the main controller determines that the detection mark has not contacted the welding wire in the wire reel and controls the driving wheel position adjustment module to adjust the position of the straightening driving wheel, thereby reducing the distance between the straightening driving wheel and the straightening driven wheel.

[0048] The straightening drive stepper motor 157 is connected to the threaded rod 154 through a coupling. The straightening drive stepper motor 157 is mounted on a stepper motor mounting bracket 158, and the stepper motor mounting bracket 158 ​​is fixed to the outside of the wire feeding motor mounting bracket 137 in the wire feeding mechanism assembly 130 by bolts.

[0049] like Figure 4 As shown, the wire feeding and straightening integrated welding gun device is installed on the execution end of the external humanoid welding robot's mechanical arm. The specific connection is to fix the outer rotor of the pan-tilt motor in the end rotating pan-tilt through bolt connection. The end rotating pan-tilt enables the humanoid welding robot to use the wire feeding and straightening integrated welding gun device to rotate 360° under the CAN communication control of the external humanoid welding robot.

[0050] like Figure 5 As shown, the main controller 170 includes a main control chip 171, a CAN communication module 172, a protective gas valve control module 173, an adaptive welding wire straightening detection module 174, a straightening stepper motor control module 175, a PMSM-FOC dual drive control module 176 and a system over-temperature and over-voltage protection module 177.

[0051] The CAN communication module 172 is connected to the CAN function pins of the main control chip 171. CAN protocol signals are converted by the CAN chip to enable communication with an external humanoid welding robot. The shielding gas valve control module 173 is connected to the GPIO function pins of the main control chip 171. This module outputs a switching signal to the valve relay to control the shielding gas control kit 110. The adaptive wire alignment detection module 174 is connected to the GPIO function pins of the main control chip 171. It is connected to the alignment drive wheel 152 and the detection mark 156 in the alignment mechanism assembly 150, transmitting a voltage signal to determine the amount of welding wire. If the detection mark 156 is not in contact with the welding wire in the wire spool 140, it inputs a 5V voltage signal to the main control chip 171, indicating that the welding wire is low. The main control chip 171 then controls the alignment stepper motor control module 175 to push the alignment drive wheel 152 in the alignment mechanism assembly 150 upward. The straightening stepper motor control module 175 is connected to the PWM function pin of the main control chip 171, and the straightening stepper motor control module 175 outputs a control signal to the straightening drive stepper motor 157 in the straightening mechanism assembly 150. The PMSM-FOC dual-drive control module 176 is connected to the PWM function pin, ADC function pin, and TIMER function pin of the main control chip 171. The PMSM-FOC dual-drive control module 176 includes a motor driver chip DRV8301 and a three-phase inverter. The PWM pin of the main control chip 171 can output drive control signals to the wire feeding PMSM motor 137 in the wire feeding mechanism assembly 130 and the pan-tilt motor 161 in the terminal rotating pan-tilt table 160, and output encoder data of the wire feeding motor encoder 138 in the wire feeding mechanism assembly 130 and the pan-tilt motor 161 in the terminal rotating pan-tilt table 160 to the TIMER pin of the main control chip 171. The PMSM-FOC dual-drive control module 176 also uses sampling resistors and op amps to collect current data from the wire-feeding PMSM motor 137 and the pan / tilt motor 161, outputting this data to the ADC pins of the main control chip 171 for closed-loop torque control. The system overtemperature and overvoltage protection module 177 is connected to the ADC pins of the main control chip 171. It uses a voltage divider resistor to collect the system supply voltage to determine if overvoltage damage is occurring, and uses a thermistor to collect the system temperature to determine if high-temperature damage is occurring. The main control chip 171 then issues a damage warning to the external humanoid welding robot via the CAN communication module 172.

[0052] The present invention meets the needs of humanoid welding robots to carry out difficult welding tasks and complete flexible welding movements under complex environmental conditions; it integrates a welding gun, a wire feeder, a shielding gas control and a welding wire straightening mechanism into one, which is installed on the end of the mechanical arm of the humanoid welding robot for use, adopts a high-precision servo PMSM to realize wire feeding control, has an adaptive welding wire straightening adjustment function, is equipped with a CAN communication interface, and has an end rotating pan-tilt table to realize 360° rotation of the device; the humanoid welding robot can realize communication control of the humanoid welding robot with the wire feeding and straightening integrated welding gun device of the present invention to perform high-precision and stable welding wire feeding, welding shielding gas output and welding gun posture adjustment, and at the same time, during the welding operation, adaptive welding wire straightening adjustment is performed as the amount of remaining welding wire on the wire reel decreases.

[0053] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. A wire feeding and straightening integrated welding gun device for a humanoid welding robot, characterized by: The welding gun comprises a main body, a wire reel, a wire feeding mechanism assembly for feeding the welding wire forward, a straightening mechanism assembly for straightening the welding wire, and a main controller; the wire reel, straightening mechanism assembly, wire feeding mechanism assembly, and welding gun main body are sequentially arranged along the welding wire feeding path; the main controller comprises a main control chip; the main control chip is respectively connected to the welding gun main body, wire feeding mechanism assembly, and straightening mechanism assembly for signal communication; The straightening mechanism assembly includes a straightening mechanism housing with a straightening inner cavity, a straightening driving wheel, a straightening driven wheel, a driving wheel position adjustment module, and a residual amount detection module for detecting the amount of remaining welding wire in the wire reel; the straightening driving wheel and the straightening driven wheel are both located in the straightening inner cavity, and the straightening driving wheel and the straightening driven wheel are staggered to form a welding wire straightening channel; The straightening driven wheel is rotatably connected to the straightening inner cavity wall; the straightening driving wheel is rotatably arranged on the driving wheel position adjustment module, and the driving wheel position adjustment module is connected to the straightening mechanism housing to achieve position adjustment of the straightening driving wheel; According to the amount of remaining welding wire on the wire reel detected by the residual detection module, the driving wheel position adjustment module adjusts the position of the straightening driving wheel to adjust the distance between the straightening driving wheel and the straightening driven wheel, thereby adjusting the straightening force on the welding wire; the smaller the amount of remaining welding wire on the wire reel, the smaller the distance between the straightening driving wheel and the straightening driven wheel; The residual detection module includes a detection mark; one end of the detection mark is connected to the driving wheel position adjustment module to adjust the position synchronously with the straightening driving wheel; the other end of the detection mark extends into the wire reel; the detection mark is connected to the high-level signal; the straightening driving wheel is connected to the GND level signal; According to the amount of remaining wire on the wire reel detected by the residual detection module, the driving wheel position adjustment module adjusts the position of the straightening driving wheel, which means: judging the amount of remaining wire on the wire reel according to the output level signal of the detection mark: When the detection mark outputs a GND level signal, the main controller determines that the detection mark is connected to the straightening active wheel signal through the welding wire, and the detection mark is in contact with the welding wire in the wire reel, and the active wheel position adjustment module does not adjust the straightening active wheel position; When the detection mark outputs a high-level signal, the main controller determines that the detection mark does not contact the welding wire in the wire reel, and controls the driving wheel position adjustment module to adjust the position of the straightening driving wheel to reduce the distance between the straightening driving wheel and the straightening driven wheel.

2. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 1, characterized in that: The driving wheel position adjustment module includes a screw-nut transmission mechanism, a straightening drive stepper motor, and a stepper motor mounting bracket; the straightening drive stepper motor is disposed on the stepper motor mounting bracket; the straightening drive stepper motor is connected to the screw-nut transmission mechanism; the straightening driving wheel is rotatably disposed on the nut structure of the screw-nut transmission mechanism; one end of the detection mark is connected to the nut structure of the screw-nut transmission mechanism; The nut structure of the screw-nut transmission mechanism is also slidably connected to the straightening inner cavity wall through a slide rail to achieve sliding direction and position limiting.

3. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 2, characterized in that: The main controller also includes an adaptive welding wire straightening detection module and a straightening stepper motor control module; The adaptive welding wire straightening detection module is connected to the GPIO function pin of the main control chip, and the adaptive welding wire straightening detection module is connected to the straightening active wheel and the detection mark in the straightening mechanism assembly to transmit a level signal for judging the remaining amount of welding wire in the wire reel; the straightening stepper motor control module is connected to the PWM function pin of the main control chip, and the straightening stepper motor control module outputs a control signal to the straightening drive stepper motor in the straightening mechanism assembly.

4. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 1, characterized in that: There are more than two straightening driven wheels; a welding wire straightening inlet and a welding wire straightening outlet are respectively provided on both sides of the straightening mechanism shell, and the centers of the welding wire straightening inlet, the welding wire straightening outlet and the welding wire inlet of the wire feeding mechanism assembly are located on a spatial straight line tangent to the lower edges of all the straightening driven wheels.

5. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 1, characterized in that: The welding wire reel frame includes a welding wire reel support frame, a welding wire reel, a damping shaft and a welding wire limiting mechanism; the damping shaft is installed on the welding wire reel support frame, and the welding wire reel is sleeved on the damping shaft; the welding wire limiting mechanism is installed on the welding wire reel support frame, and is used to press the edge of the welding wire reel to prevent the welding wire from falling off.

6. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 1, characterized in that: It also includes a shielding gas control kit; the shielding gas control kit includes a shielding gas electromagnetic valve and a valve outlet pipe; the shielding gas electromagnetic valve is connected to an external shielding gas supply device and is installed on the wire feeding mechanism assembly; the valve outlet pipe is connected between the shielding gas electromagnetic valve and the welding gun body.

7. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 6, characterized in that: The welding gun body includes a copper conductive nozzle, a diverter and a nozzle connecting section, a copper conductive body, a wire feed guide tube and a shielding gas joint; the copper conductive nozzle, the diverter and the nozzle connecting section and the copper conductive body are connected to each other, and the center axes are located on the same spatial straight line; the wire feed guide tube is sleeved inside the copper conductive body; the shielding gas joint is connected to the upper part of the copper conductive body, and the shielding gas joint is connected to the gas valve outlet pipe in the shielding gas control kit; the welding wire entry end of the copper conductive body has a thread and is fixed with a nut to the welding cable terminal connected to the external welding power supply.

8. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 7, characterized in that: The wire feeding mechanism assembly includes an active wire feeding gear, a wire feeding pressing gear, a pressing gear adjusting handle, a wire feeding assembly housing, a wire guide nozzle, a wire feeding PMSM motor, a wire feeding motor mounting bracket and a wire feeding motor encoder; the active wire feeding gear is installed in the wire feeding assembly housing; the wire feeding pressing gear is connected to the pressing gear adjusting handle and is installed above the active wire feeding gear; the wire feeding pressing gear is engaged with the active wire feeding gear when there is no welding wire, and is used to press the welding wire and push the welding wire out when there is welding wire; the pressing gear adjusting handle is used to preset the pressing force on the welding wire; the welding wire inlet and the welding wire outlet of the wire feeding mechanism assembly are respectively located at the outer ends of the wire feeding assembly housing. On both sides; the meshing lines of the welding wire inlet, the welding wire outlet, the active wire feeding gear and the wire feeding pressing gear are on a straight line in space; the welding wire outlet of the wire feeding assembly housing is connected to the welding gun body; the wire guide nozzle is installed at the welding wire inlet to guide the welding wire into the wire feeding mechanism assembly; the wire feeding motor mounting bracket is installed below the wire feeding assembly housing; the wire feeding PMSM motor is fixed in the wire feeding motor mounting bracket, and the output shaft of the wire feeding PMSM motor is perpendicular to the central axis of the active wire feeding gear in space, and the wire feeding torque is transmitted through the worm gear; the wire feeding motor encoder is installed at the bottom of the wire feeding motor mounting bracket, below the wire feeding PMSM motor; The wire feeding mechanism assembly is connected to a terminal rotating pan-tilt platform; the terminal rotating pan-tilt platform includes a pan-tilt platform motor and a pan-tilt platform bracket; the pan-tilt platform bracket is installed below the wire feeding motor mounting bracket in the wire feeding mechanism assembly, and the pan-tilt platform motor is installed in the pan-tilt platform bracket.

9. The wire feeding and straightening integrated welding gun device for a humanoid welding robot according to claim 8, characterized in that: The main controller also includes a CAN communication module, a protective gas valve control module, a PMSM-FOC dual drive control module and a system over-temperature and over-voltage protection module; The CAN communication module is connected to the CAN function pin of the main control chip and communicates with the external humanoid welding robot through a CAN communication cable; the shielding gas valve control module is connected to the GPIO function pin of the main control chip, and the shielding gas valve control module outputs a control signal to the shielding gas control kit; the PMSM-FOC dual-drive control module is respectively connected to the PWM function pin, ADC function pin and TIMER function pin of the main control chip, and the PMSM-FOC dual-drive control module outputs a drive control signal to the wire feeding PMSM motor in the wire feeding mechanism assembly and the pan-tilt motor in the end rotating pan-tilt and receives encoder data from the wire feeding motor encoder in the wire feeding mechanism assembly and the pan-tilt motor in the end rotating pan-tilt; the system over-temperature and overvoltage protection module is connected to the ADC function pin of the main control chip.

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