An intrinsically safe welding device with intelligent protection

Abstract

The application discloses an intelligent protection intrinsically safe welding device, and relates to the technical field of metal welding equipment.The scheme realizes efficient welding of high-temperature alloy by precisely controlling the stability of an electric arc and the flow of protective gas, automatically adjusts on-off power states in the welding process by the design of an edge power supply and a power-off responder, and improves the safety of welding.The linkage system of photoelectric sensors and gas sensors ensures that welding is started under suitable conditions and quickly powered off when combustible gas is detected, preventing accidents.The device can effectively control the splashing of welding slag in vertical and inclined welding conditions during the welding process, and the flexible design of the protective kit ensures the stability and safety of the welding operation.Magnetic adsorption and rubber sleeve plates cooperate to increase the adaptability of the device, which is suitable for welding of workpieces of different shapes, further improving the safety and operation efficiency.

Description

Technical Field

[0001] The present invention belongs to the technical field of metal welding equipment, and in particular relates to an intrinsically safe welding device with intrinsically safe intelligent protection and intelligent identification and automatic interlocking functions. Background Art

[0002] Electric welding is a common metal joining method that utilizes the high temperature generated by an electric arc to melt the electrode and workpiece, creating a strong weld. However, electric welding also presents certain safety risks. Sparks, smoke, and molten metal droplets generated by the arc can ignite surrounding combustible materials, leading to fire accidents. This is especially true when welding in flammable and explosive locations such as hospitals, gas stations, and chemical plants. Safety and protection during welding operations are extremely important. The risk factor for welding operations is far higher than other work, and every detail is crucial. To prevent fire accidents caused by electric welding, several protective measures have been proposed in the prior art, such as covering surrounding combustibles with flame-retardant materials, installing fire extinguishers in the welding area, and ensuring that personnel supervise the welding process. Patent applications such as "A Flame-Retardant ABS Plastic, Its Preparation Method, and Its Application in Welding Machine Housings and Welding Auxiliary Plastic Tools" (CN202011514184.5), "A Welding Fume Safety Protection Auxiliary Device" (CN201910851351.6), and "A Safety Protection Cart for Welding Machines" (CN201820745305.9) can protect welders and prevent fires to a certain extent. However, these measures are passive and external, and cannot fundamentally eliminate the possibility of fires caused by electric welding. Furthermore, these measures also have certain limitations and inconveniences, such as the possibility that flame-retardant materials may not be sufficient to cover all combustibles, fire extinguishers may not be available in time or used improperly, and the possibility of distracted or negligent supervision.

[0003] In summary, when dangerous fire sources such as sparks, high temperatures, and slag splashing caused by high temperature of the welding arc, roadblocks of the welding machine and lines, old and overloaded lines, and overheating of cable joints occur, it is often impossible to stop the operation in time, isolate the dangerous area from the workers, and thus cannot ensure the safety of on-site workers.

[0004] At the same time, in current welding devices, arc welding has certain risks, and there is a lot of room for improvement in terms of improving the safety of use.

[0005] In view of this, the present invention is proposed. Summary of the Invention

[0006] To solve the above technical problems, the present invention adopts a technical solution with the following basic concept: an intrinsically safe welding device with intelligent protection, comprising a transfer chamber, an electric control chamber disposed above the transfer chamber, an inner wall of the electric control chamber being provided with a detection auxiliary device connected to the transfer chamber, and a gas sensor connected to the detection auxiliary device being mounted on the upper surface of the electric control chamber;

[0007] An airtight interface is installed on one side of the transfer chamber, and a buffer seal is sealed on the other side of the transfer chamber. Two clamps for fixing are provided at both ends of the buffer seal. A welding head assembly is installed on one side of the buffer seal, and the welding head assembly is connected to the transfer chamber through the buffer seal.

[0008] A photoelectric sensor is installed on the lower surface of the buffer seal, and a response component is fixedly connected to the inner wall of the transfer bin, and the response component is electrically connected to the photoelectric sensor;

[0009] An edge power supply is fixed through one side of the inner wall of the electrical control room, the edge power supply is electrically connected to a power failure responder, the power failure responder is electrically connected to the welding head assembly through an electrical connector, and the edge power supply is connected to the gas sensor;

[0010] The surface of the welding head assembly is movably connected with a protective kit;

[0011] The invention also comprises a welding machine, wherein a processor is provided on the surface of the welding machine, an automatic interlocking device is provided on one side of the welding machine, and the welding machine is connected to a gas cylinder.

[0012] Preferably, the detection aid includes a venturi tube fixedly connected to the inner wall of the electric control room, a sampling tube is provided on one side of the narrow mouth of the venturi tube, the top of the venturi tube is connected to the gas sensor, a pressure relief hole is provided at the bottom end of the venturi tube, and the venturi tube is connected to the transfer chamber through the pressure relief hole, the sampling tube is fixedly connected to the top ends of the two clamps, and a filter cotton is provided at one end of the sampling tube.

[0013] Preferably, the welding head assembly includes a bend pipe connected to the buffer seal seat, a conductive core is installed at the bottom end of the bend pipe, and a discharge head is fixedly connected to the bottom end of the conductive core;

[0014] The surface of the conductive core is fixedly connected with a quick-release connector, the bottom end of the quick-release connector is installed with a constriction mask, the inner wall of the constriction mask is installed with a uniform flow cover, the arc-shaped side wall of the conductive core is evenly provided with a plurality of transfer holes, and the surface of the uniform flow cover is provided with a plurality of uniform flow holes;

[0015] A rotating sleeve is rotatably provided on the surface of the quick-release joint.

[0016] Preferably, the buffer seal includes an airtight joint that is limitedly slidable on the inner wall of the transfer chamber, one end of the airtight joint is fixed with a clamping seat, the other side of the clamping seat is fixedly connected to a tensioning head, the surface of the tensioning head is provided with an electric socket, and the tensioning head is fixed to the top of the welding head assembly through the electric socket;

[0017] The tensioning head is provided with a flexible cover at one end opposite to the transfer chamber, and two clamps are respectively located at both ends of the flexible cover to fix it;

[0018] The lower surface of the power socket is fixedly connected to the photoelectric sensor.

[0019] Preferably, the protective kit includes an extension frame movably connected to both sides of the rotating sleeve through a pin shaft, one side of the extension frame is rotatably provided with a rotating connector, one end of the rotating connector is rotatably connected to a rubber sleeve, and the inner wall of the rubber sleeve is fixed with a shaping rib;

[0020] A plurality of metal strips with convex ends are slidably passed through the surface of the rubber sleeve, and a plurality of magnets are attached to one side of the rubber sleeve.

[0021] Preferably, the response component includes a support frame fixedly connected to the inner wall of the transfer bin, the support frame is fixedly connected to a generator, and a fan blade is provided on the surface of the generator.

[0022] Preferably, a display is provided on the surface of the welder, the welder is connected to the welding head assembly and the gas cylinder through an airtight interface, and the welder is provided with an alarm.

[0023] Preferably, the photoelectric sensor and the gas sensor are communicatively connected to the processor, and the automatic interlocking device includes a relay.

[0024] Preferably, a valve is provided on the lower surface of the transfer chamber, and the valve is connected to a corrugated tube for diverting the gas in the transfer chamber.

[0025] Preferably, a power supply line is provided on one side of the edge power supply, and the power supply line is electrically connected to the welding machine, and a handle is installed on the surface of the airtight interface.

[0026] Beneficial effects:

[0027] This solution achieves efficient welding of high-temperature alloys by precisely controlling the stability of the arc and the flow of shielding gas. The design of an edge power supply and a power-off responder automatically adjusts the power-on and power-off states during welding, improving welding safety. The linkage system of photoelectric sensors and gas sensors ensures that welding is started under appropriate conditions, and quickly shuts off the power when combustible gas is detected to prevent accidents. During welding, the equipment can effectively control the splashing of welding slag in vertical and tilted welding conditions, and the flexible design of the protective kit ensures the stability and safety of the welding operation. At the same time, the magnetic adsorption system and rubber sleeve increase the adaptability of the equipment, making it suitable for welding workpieces of different shapes, further improving its safety and operational efficiency.

[0028] This device intelligently identifies the relative position of the welding head assembly and the workpiece, preventing welding from igniting surrounding combustibles. If the relative position of the two is abnormal, the welding head assembly automatically disconnects and stops functioning. The invention also provides combustible gas monitoring, enabling timely monitoring of combustible gas concentrations and automatic power-off protection. The welding head assembly nozzle is prevented from coming into contact with combustible gases, thus ensuring the inherent safety of the welding device.

[0029] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In the attached figure:

[0031] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0032] Figure 2 It is a schematic diagram of a partial three-dimensional structure of the present invention;

[0033] Figure 3 A schematic diagram of a partial three-dimensional structure of the present invention from another viewing angle;

[0034] Figure 4 It is a three-dimensional structural diagram of the protective kit of the present invention;

[0035] Figure 5 This is a structural diagram of the cross section of the transfer compartment and the electric control room of the present invention;

[0036] Figure 6 Schematic diagram of the three-dimensional cross-sectional structure of the welding head assembly of the present invention;

[0037] Figure 7 This is a schematic diagram of the explosion structure of the electric control room of the present invention;

[0038] Figure 8 This is a schematic diagram of the three-dimensional cross-sectional structure of the transfer bin of the present invention;

[0039] Figure 9Schematic diagram of the three-dimensional cross-sectional structure of the response component of the present invention;

[0040] Figure 10 It is a schematic diagram of the three-dimensional cross-sectional structure of the buffer seal of the present invention.

[0041] In the figure: 1. Transfer chamber; 2. Electric control room; 3. Airtight interface; 4. Buffer seal; 41. Card seat; 42. Tensioning head; 43. Electric seat; 44. Airtight joint; 45. Flexible cover; 5. Welding head assembly; 51. Bend pipe; 52. Conductive core; 53. Quick release connector; 54. Mask; 55. Flow hood; 56. Discharge head; 57. Flow hole; 58. Flow hole; 59. Rotating sleeve; 6. Response assembly; 61. Support frame; 62. Generator; 63. Fan blade; 7. Detection aid; 71. Venturi tube; 72. Sampling Tube; 73. Pressure relief vent; 8. Protective kit; 81. Extension bracket; 82. Rotary connector; 83. Rubber sleeve; 84. Shaping rib; 85. Metal strip; 86. Magnet; 9. Edge power supply; 10. Power failure responder; 11. Connector; 12. Gas sensor; 13. Power supply line; 14. Valve; 15. Corrugated tube; 16. Clamp; 17. Photoelectric sensor; 18. Filter cotton; 19. Handle; 20. Welding machine; 21. Gas cylinder; 22. Automatic interlocking device; 23. Processor; 24. Display; 25. Alarm. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention.

[0043] like Figures 1 to 10 As shown, an intrinsically safe welding device with intelligent protection includes a transfer chamber 1, an electric control room 2 is provided above the transfer chamber 1, a detection auxiliary device 7 connected to the transfer chamber 1 is provided on the inner wall of the electric control room 2, and a gas sensor 12 connected to the detection auxiliary device 7 is installed on the upper surface of the electric control room 2;

[0044] An airtight interface 3 is installed on one side of the transfer chamber 1, and a buffer seal 4 is sealed and installed on the other side of the transfer chamber 1. Two clamps 16 are provided at both ends of the buffer seal 4 for fixing. A welding head assembly 5 is installed on one side of the buffer seal 4, and the welding head assembly 5 is connected to the transfer chamber 1 through the buffer seal 4;

[0045] A photoelectric sensor 17 is installed on the lower surface of the buffer seal 4, and a response component 6 is fixedly connected to the inner wall of the transfer chamber 1. The response component 6 is electrically connected to the photoelectric sensor 17;

[0046] An edge power supply 9 is fixed through one side of the inner wall of the electric control room 2. The edge power supply 9 is electrically connected to a power failure responder 10. The power failure responder 10 is electrically connected to the welding head assembly 5 through an electrical connector 11. The edge power supply 9 is connected to a gas sensor 12.

[0047] The surface of the welding head assembly 5 is movably connected with a protective kit 8;

[0048] The device further comprises a welding machine 20 , a processor 23 is provided on the surface of the welding machine 20 , an automatic interlocking device 22 is provided on one side of the welding machine 20 , and the welding machine 20 is connected to a gas cylinder 21 .

[0049] Specifically, such as Figure 1 As shown: the detection auxiliary device 7 includes a venturi tube 71 fixedly connected to the inner wall of the electric control room 2, a sampling tube 72 is provided on one side of the narrow mouth of the venturi tube 71, the top of the venturi tube 71 is connected to the gas sensor 12, a pressure relief hole 73 is provided at the bottom end of the venturi tube 71, and is connected to the transfer chamber 1 through the pressure relief hole 73, the sampling tube 72 is fixedly connected to the top of the two clamps 16, and a filter cotton 18 is provided at one end of the sampling tube 72.

[0050] By providing the Venturi tube 71 , a suction force can be generated on one end of the sampling tube 72 through the Venturi effect, so that the external air can be drawn in.

[0051] The clamp 16 can provide auxiliary support for the sampling tube 72 to maintain the stability of the installation, and the sampling tube 72 can be bent at a certain angle.

[0052] Specifically, such as Figure 1 As shown: the welding head assembly 5 includes a bend pipe 51 connected to the buffer seal 4, a conductive core 52 is installed at the bottom end of the bend pipe 51, and a discharge head 56 is fixedly connected to the bottom end of the conductive core 52;

[0053] A quick-release connector 53 is fixedly connected to the surface of the conductive core 52. A constriction cover 54 is installed at the bottom end of the constriction cover 53. A uniform flow cover 55 is installed on the inner wall of the constriction cover 54. A plurality of transfer holes 58 are evenly opened on the curved side wall of the conductive core 52. A plurality of uniform flow holes 57 are opened on the surface of the uniform flow cover 55.

[0054] A rotating sleeve 59 is rotatably provided on the surface of the quick-release joint 53 .

[0055] The uniform flow cover 55 is located on the surface of the conductive core 52. The conductive core 52 can retain the protective gas in the uniform flow cover 55. The uniform flow holes 57 on the surface of the uniform flow cover 55 keep the gas flowing out evenly to the surroundings, forming a uniform flow rate wrapped airflow around the discharge head 56.

[0056] Specifically, such as Figure 10As shown: the buffer seal 4 includes an airtight joint 44 that is limitedly slidable on the inner wall of the transfer chamber 1. A clamping seat 41 is fixed to one end of the airtight joint 44. A tensioning head 42 is fixedly connected to the other side of the clamping seat 41. A power socket 43 is provided on the surface of the tensioning head 42, and the tensioning head 42 is fixed to the top of the welding head assembly 5 through the power socket 43.

[0057] The tensioning head 42 is provided with a flexible cover 45 at one end opposite to the transfer chamber 1, and two clamps 16 are respectively located at both ends of the flexible cover 45 to fix it;

[0058] The lower surface of the power socket 43 is fixedly connected to the photoelectric sensor 17 .

[0059] The airtight joint 44 is subjected to the action of air pressure and can be tightly combined with the inner wall of the buffer seal 4. At the same time, the surface is further sealed and fixed by the flexible cover 45. This design can maintain the support state and seal through internal pressure position. At the same time, the welding head assembly 5 is subjected to a large force, the movable joint can be displaced, and the flexible cover 45 is deformed accordingly, which can prevent the welding head assembly 5 from being damaged by external forces such as impact, and has a good protective effect. At the same time, it can prevent the welding head assembly 5 from being electrically connected to the adapter bin 1, and has a good insulation effect.

[0060] Specifically, such as Figure 9 As shown, the response component 6 includes a support frame 61 fixedly connected to the inner wall of the transfer chamber 1, the support frame 61 is fixedly connected to a generator 62, and a fan blade 63 is provided on the surface of the generator 62.

[0061] The support frame 61 supports the generator 62. Under the action of the fan blades 63 on the surface, the generator 62 rotates at high speed under the action of the airflow and generates electricity. Driven in this way, the response can be guaranteed to be stable, accurate and reliable.

[0062] Specifically, such as Figure 1 As shown, a display 24 is provided on the surface of the welding machine 20. The welding machine 20 is connected to the welding head assembly 5 and the gas cylinder 21 through the airtight interface 3. The welding machine 20 is provided with an alarm 25. The photoelectric sensor 17 and the gas sensor 12 are communicatively connected to the processor 23. The automatic interlocking device 22 includes a relay.

[0063] The display 24 can display the overall operating status and information, and through the alarm 25, an alarm can be issued after power failure, thereby improving safety in use.

[0064] Specifically, such as Figure 4 As shown, a valve 14 is provided on the lower surface of the transfer chamber 1 , and the valve 14 is connected to a bellows 15 for diverting the gas in the transfer chamber 1 .

[0065] The valve 14 can control the connectivity status of the bottom of the transfer chamber 1, and can allow the airflow to protect the molten pool through the welding head assembly 5. This method can guide part of the airflow into the corrugated tube 15 and blow it obliquely toward the molten pool through the corrugated tube 15, so as to realize multi-angle protective gas diversion and common welding protection, and at the same time can controllably converge the welding slag.

[0066] A power supply line 13 is provided on one side of the edge power supply 9 , and the power supply line 13 is electrically connected to the welding machine 20 . A handle 19 is installed on the surface of the airtight interface 3 .

[0067] Gas sensor 12 monitors the concentration of combustible gases within the welding area, such as hydrogen, methane, and acetylene, and transmits the monitoring results as electrical signals to processor 23, ensuring safe monitoring during the welding operation. This detachable design ensures real-time safety monitoring during welding operations, making the entire welding device more intelligent, efficient, and safer.

[0068] The welding head assembly 5 is used to generate an arc. A high-precision photoelectric sensor 17 is provided on the surface of the buffer seal 4 to monitor the relative position of the welding head assembly 5 and the workpiece, such as distance, angle, etc., and send the monitoring results to the processor 23 in the form of an electrical signal. If the relative position of the two is abnormal, the power-off responder 10 will automatically disconnect and stop working.

[0069] The processor 23 receives multiple data such as the pressure and flow of the gas sensor 12, the photoelectric sensor 17, and the gas cylinder 21 to realize parameter collection and fusion, and identify abnormalities in combination with the threshold. At the same time, it also has a fault recording function, which can record and save historical fault information, providing an important reference for subsequent troubleshooting and maintenance. The processor 23 has a built-in abnormality identification algorithm based on the Z-Score method. If the absolute value of the Z-Score of a parameter exceeds the set threshold, the parameter is considered to be in an abnormal state. This threshold can be adjusted according to the actual situation. The specific steps are as follows:

[0070] (1) Data preparation and preprocessing: including data collection, data cleaning and data standardization. Real-time data collection (gas sensor 12, photoelectric sensor 17 and pressure and flow of gas cylinder 21, etc.), including combustible gas concentration, relative position of welding (distance, angle, etc.), gas pressure and flow (the power generation of response component 6 is proportional to it). The collected raw data is cleaned to remove noise, missing values ​​or outliers to ensure the accuracy of subsequent analysis. For parameters of different dimensions and magnitudes, they are converted into unitless values ​​through standardization so that different parameters can be compared and analyzed;

[0071] (2) Abnormality judgment: First, based on historical data or real-time data over a period of time, calculate the mean μ and standard deviation σ of each parameter, which represent the normal center value of the parameter and the degree of dispersion of the data point relative to the mean, respectively. During the welding process, the data of each parameter is collected in real time by sensors and calculated using the Z-Score formula: Z=(x-μ) / σ, where x is the value of the current real-time data point. The calculated Z-Score value is compared with the preset threshold. If the absolute value of the Z-Score of a parameter exceeds the threshold, the parameter is judged to be in an abnormal state, which means that the current value of the parameter has significantly deviated from the normal range, which may indicate potential problems or risks.

[0072] (3) Emergency response: When the sensor detects that the relative position of the welding head assembly 5 and the workpiece is abnormal (such as the distance is too far or too close, the angle is too large or too small, etc.), the processor 23 automatically controls the power-off responder 10 to cut off the power, so that the welding head assembly 5 stops working. The alarm 25 is used to connect with the processor 23 and the automatic interlocking device 22. When the processor 23, the power-off responder 10 or the automatic interlocking device 22 sends a signal to stop working, the alarm 25 sends an audible and visual alarm to remind the operator and surrounding personnel to pay attention to safety; the processor 23 is used to process various data in the arc welding process in real time, including combustible gas monitoring data, gas consumption, welding quality parameters, etc., to ensure welding quality while preventing the reactive consumption of flame-retardant gas; the display 24 is connected to the processor 23 to display the relative position of the welding head assembly 5 and the workpiece, the working status of the welding head assembly 5, and other information in real time, so that the operator and management personnel can monitor and adjust the welding process conveniently. When the welding process is abnormal, the display 24 displays the cause of the abnormality and provides the operator with precise adjustment guidance based on the solution preset in the processor 23. For example, when the photoelectric sensor 17 detects an abnormality in the relative position of the welding head assembly 5 and the workpiece, the display 24 will immediately display the corresponding error message "Abnormal relative position of the welding head assembly 5 and the workpiece". Then, the display 24 will further refine the abnormality description based on the precise distance and angle data transmitted back by the sensor, such as "The welding head assembly 5 is too far from the workpiece" or "The angle between the welding head assembly 5 and the workpiece is too small". At the same time, the solution area on the display 24 will be updated synchronously to provide the operator with specific adjustment suggestions. These suggestions may include "Move the welding head assembly 5 back 30cm" or "Rotate the welding head assembly 5 30° clockwise". As the operator makes adjustments, the sensor will continue to sense and feedback the latest distance and angle information until the display 24 displays the prompt "Adjustment completed, you can continue the operation", indicating that the relative position of the welding head assembly 5 and the workpiece has returned to normal and the welding operation can continue safely. Throughout the entire process, Display 24 not only serves as the "eyes" for monitoring the welding process, but also serves as a powerful assistant for operators, helping them quickly identify problems and find solutions in complex and changing welding environments, ensuring efficient and safe welding operations.

[0073] This solution utilizes intelligent identification and control through multiple sensors and controllers to monitor the relative position of the welding head assembly 5 and the workpiece in real time, ensuring that a safe distance and angle are maintained throughout the welding process. This mechanism prevents sparks, smoke, and molten droplets caused by abnormal relative positioning of the welding head assembly 5 and the workpiece from igniting surrounding combustible materials, significantly reducing the risk of fire accidents caused by electric welding.

[0074] The entire device integrates combustible gas monitoring, welding data collection, and automatic power-off protection, forming a closed-loop safety protection network. This device can promptly detect and shut down dangerous situations where combustible gas concentrations are too high, ensuring that explosions caused by excessive combustible gas concentrations do not occur during the welding process.

[0075] The alarm 25 and display 24 provide audible and visual warnings and information display, providing timely reminders to the operator and surrounding personnel. Furthermore, the display 24 displays real-time information such as the relative position of the welding head assembly 5 and the workpiece, the operating status of the welding head assembly 5, and other information, making it easier for operators and managers to monitor and adjust the welding process. This intuitive human-machine interface provides greater convenience and efficiency.

[0076] Compared to traditional fire and explosion prevention measures, the intelligently protected intrinsically safe welding device of the present invention implements information-based protective measures. By integrating various sensors, controllers, and displays 24, the device can collect, process, and display various data and information from the welding process in real time, making safety measures more precise and efficient. This information-based protective measure not only improves safety but also reduces the possibility of misoperation and negligence.

[0077] The intelligently protected intrinsically safe welding device of this invention provides an active, internal, and automated protective measure. It eliminates the need for passive, external, and manual protective measures, such as additional fire extinguishing equipment and dedicated monitoring, thereby saving costs and improving efficiency. This active, internal, and automated protective measure makes the welding process safer and more reliable.

[0078] When this solution is used, it includes the following working modes:

[0079] In this embodiment, the welding machine 20 supplies power to the edge power supply 9 via the power supply line 13. The edge power supply 9 transmits current through the contact head 11 and the contact socket 43 to energize the welding head assembly 5. When the welding head contacts the workpiece and moves slightly away, the high electric field intensity ionizes the gas molecules in the air or shielding gas (such as argon or carbon dioxide), forming a plasma. This plasma contains a large number of free electrons and positive ions. Under the influence of the electric field, the free electrons flow from the welding head to the workpiece, while the positive ions move toward the welding head. This process forms a stable arc between the welding head and the workpiece. The electrons and ions in the arc collide with each other at high energy, releasing a large amount of heat energy, melting the materials of the welding head and the workpiece.

[0080] A power outage responder 10 is provided between the edge power supply 9 and the power connector 11. The response mechanism of the power outage responder 10 is as follows:

[0081] First:

[0082] The welder 20 supplies power to the edge power supply 9, and at the same time, the solenoid valve in the welder 20 opens, and the protective gas in the gas cylinder 21 enters the airtight interface 3 through welding, so that the high-pressure gas drives the generator 62 to start operation. If the gas pressure is insufficient, the generator 62 will not generate enough power, and the photoelectric sensor 17 cannot be activated;

[0083] If the air pressure is normal, the high-speed flow of protective gas carries the generator 62 to meet the power demand of the photoelectric sensor 17. The photoelectric sensor 17 detects the distance between the welding head assembly 5 and the workpiece. When the distance is appropriate, the photoelectric sensor 17 feeds back a start signal. If the distance between the welding head assembly 5 and the workpiece is far, the photoelectric sensor 17 feeds back a stop signal.

[0084] The start signal and the stop signal are fed back to the power-off responder 10 to make it respond to power on and off. When the welding head assembly 5 is at a certain distance from the workpiece, the power is automatically cut off, ensuring safer use.

[0085] Second:

[0086] When in use, when high-pressure gas enters the transfer chamber 1 through the airtight interface 3, high-pressure air is formed in the transfer chamber 1, and the high-pressure air enters the welding head assembly 5 through the buffer seal 4;

[0087] At the same time, a small amount of high-pressure air enters the venturi tube 71 and forms a high-speed airflow at the narrow opening of the venturi tube 71. Under the action of the high-speed airflow, a negative pressure is formed in the sampling tube 72, so that the air at the end of the welding head can be extracted and enter the venturi tube 71, and then enter the gas sensor 12 in the high-speed airflow.

[0088] The detection of the gas sensor 12 is synchronized with the start of the protective gas. If no flammable gas is detected, there will be no response.

[0089] If flammable gas is detected, a power-off signal is sent to the processor 23, and the power-off responder 10 is quickly disconnected. At this time, the welding head assembly 5 is powered off and the flammable gas cannot be ignited;

[0090] Third:

[0091] In this solution, if a short circuit occurs in the welding machine 20, the automatic interlocking device 22 (relay) is in a disconnected state, thereby avoiding safety hazards such as equipment failure such as a short circuit.

[0092] Furthermore, during the welding process, it is impossible to ensure that the surrounding combustible materials are fully cleaned. The splashing welding slag poses a certain safety hazard to the surrounding combustible materials, and the welding slag is difficult to be effectively controlled. Based on this, this solution proposes the following welding method:

[0093] First:

[0094] When welding vertically:

[0095] The welding slag is different from the one-direction splashing in inclined welding. It splashes evenly all around. At this time, by opening the valve 14 and adjusting the angle of the bellows 15, the pressurized protective gas in the transfer chamber 1 passes through the valve 14 and blows out the airflow through the bellows 15. While assisting in blowing the protective gas to the molten pool, the vertical protective gas is blown by the lateral protective gas of the bellows 15, so that the splashing welding slag is guided in a fixed direction and blocked by the protective kit 8.

[0096] Second

[0097] When welding at an angle:

[0098] During the welding process, the workpiece is welded by tilting and swinging at a certain angle, so that the protective kit 8 moves accordingly during the welding displacement process. At the same time, the protective gas ejected in the tilted state blows the position of the molten pool, blowing the splashing welding slag in one direction and intercepting it by the protective kit 8, avoiding uncontrolled splashing and avoiding affecting the surrounding flammable materials.

[0099] It can be seen from the above two welding methods that welding slag can be effectively controlled and the safety of use can be improved when combustible materials in the welding environment are difficult to clean.

[0100] Specifically, such as Figure 4 As shown: the protective kit 8 includes an extension frame 81 movably connected to both sides of the rotating sleeve 59 through a pin shaft, a rotating connector 82 is rotatably provided on one side of the extension frame 81, and one end of the rotating connector 82 is rotatably connected to a rubber sleeve 83, and the inner wall of the rubber sleeve 83 is fixed with a shaping rib 84;

[0101] A plurality of metal strips 85 with convex ends are slidably provided on the surface of the rubber sleeve 83 , and a plurality of magnets 86 are attached to one side of the rubber sleeve 83 .

[0102] Based on the above-mentioned vertical welding and inclined welding, both require the cooperation of the protective kit 8, wherein the protective kit 8 has multiple active points, including the connection between the extension frame 81 and the rotating sleeve 59 through the pin shaft, which cooperates with the rotation of the rotating member to achieve flexible change of any angle, which is convenient for welding with different angles of the welding head during welding. At the same time, during the welding process, the active connection between the extension frame 81 and the rotating connector 82, as well as the rotating connection between the rotating connector 82 and the rubber sleeve 83, achieves arbitrary adjustment and change of multiple angles at this node, which can meet the stability of the protective kit 8 when it is attached to the surface of the workpiece, reduce the force applied by the welding head, and can be displaced accordingly to reduce the swing amplitude;

[0103] At the same time, any number of magnets 86 are adsorbed on the surface of the rubber sleeve 83. The number of magnets 86 is directly proportional to the magnetic force of the metal strip 85, so that the metal strip 85 can be adsorbed on the surface of the workpiece with a certain magnetic force to maintain adhesion, and the magnitude of the magnetic force is slightly changed by the number of magnets 86. At the same time, when in use, the shaping ribs 84 on the surface of the rubber sleeve 83 are bent so that the rubber sleeve 83 can be bent at different angles to facilitate the collection of spattered welding slag.

[0104] The sliding metal strip 85 , when combined with multiple metal strips 85 , can fit on the surface of metal workpieces including arcs, planes, and corners, achieving good adaptability.

[0105] At the same time, this solution requires a constant flow of protective gas to realize the operation of the photoelectric sensor 17, and the photoelectric sensor 17 serves as a prerequisite for power-on, so that it can quickly cut off the power for protection when the protective gas is insufficient or the welding distance is insufficient, thereby avoiding safety hazards. At the same time, in conjunction with the combustible gas detection method, a very small amount of protective gas is leaked, and a small amount of air can be drawn in with the sampling tube 72 to realize air detection while starting. If combustible gas is detected, the power is automatically cut off to improve safety. If the gas sensor 12 does not detect the protective gas, the detection data is invalid. If the protective gas is detected, it is determined to be in an operating state.

[0106] The above are only preferred specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. An intrinsically safe welding device with intelligent protection, comprising a transfer chamber (1), characterized in that: An electric control room (2) is provided above the transfer chamber (1), an inner wall of the electric control room (2) is provided with a detection auxiliary device (7) connected to the transfer chamber (1), and a gas sensor (12) connected to the detection auxiliary device (7) is installed on the upper surface of the electric control room (2); An airtight interface (3) is installed on one side of the transfer chamber (1), a buffer seal seat (4) is sealed and installed on the other side of the transfer chamber (1), two clamps (16) for fixing are provided at both ends of the buffer seal seat (4), a welding head assembly (5) is installed on one side of the buffer seal seat (4), and the welding head assembly (5) is connected to the transfer chamber (1) through the buffer seal seat (4); A photoelectric sensor (17) is installed on the lower surface of the buffer seal seat (4), and a response component (6) is fixedly connected to the inner wall of the transfer bin (1), and the response component (6) is electrically connected to the photoelectric sensor (17); An edge power supply (9) is fixedly provided through one side of the inner wall of the electric control room (2), the edge power supply (9) is electrically connected to a power failure responder (10), the power failure responder (10) is electrically connected to the welding head assembly (5) via an electrical connector (11), and the edge power supply (9) is connected to a gas sensor (12); The surface of the welding head assembly (5) is movably connected to a protective kit (8); The invention also comprises a welding machine (20), wherein a processor (23) is provided on the surface of the welding machine (20), an automatic interlocking device (22) is provided on one side of the welding machine (20), and the welding machine (20) is connected to a gas cylinder (21).

2. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: The detection auxiliary device (7) includes a venturi tube (71) fixedly connected to the inner wall of the electric control room (2); a sampling tube (72) is provided on one side of the narrow opening of the venturi tube (71); the top end of the venturi tube (71) is connected to the gas sensor (12); a pressure relief hole (73) is provided at the bottom end of the venturi tube (71), and the venturi tube is connected to the transfer chamber (1) through the pressure relief hole (73); the sampling tube (72) is fixedly connected to the top ends of two clamps (16); and a filter cotton (18) is provided at one end of the sampling tube (72).

3. The intelligent protection intrinsically safe welding device according to claim 1, characterized in that: The welding head assembly (5) comprises a curved tube (51) in communication with the buffer seal seat (4); a conductive core (52) is mounted at the bottom end of the curved tube (51); and a discharge head (56) is fixedly connected to the bottom end of the conductive core (52); A quick-release connector (53) is fixedly connected to the surface of the conductive core (52), a constriction mask (54) is installed at the bottom end of the constriction mask (54), a uniform flow cover (55) is installed on the inner wall of the constriction mask (54), a plurality of transfer holes (58) are evenly opened on the arc-shaped side wall of the conductive core (52), and a plurality of uniform flow holes (57) are opened on the surface of the uniform flow cover (55); A rotating sleeve (59) is rotatably provided on the surface of the quick-release joint (53).

4. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: The buffer seal (4) includes an airtight joint (44) that is limitedly slidable on the inner wall of the transfer chamber (1); a clamping seat (41) is fixed to one end of the airtight joint (44); a tensioning head (42) is fixedly connected to the other side of the clamping seat (41); a power connection seat (43) is provided on the surface of the tensioning head (42), and the tensioning head (42) is fixed to the top end of the welding head assembly (5) through the power connection seat (43); The tensioning head (42) is provided with a flexible cover (45) at one end opposite to the transfer chamber (1), and two clamps (16) are respectively located at both ends of the flexible cover (45) to fix it; The lower surface of the power receiving seat (43) is fixedly connected to the photoelectric sensor (17).

5. The intelligent protection intrinsically safe welding device according to claim 3, characterized in that: The protective kit (8) comprises an extension frame (81) movably connected to both sides of the rotating sleeve (59) via a pin shaft, a rotating connector (82) is rotatably provided on one side of the extension frame (81), one end of the rotating connector (82) is rotatably connected to a rubber sleeve (83), and a shaping rib (84) is fixed to the inner wall of the rubber sleeve (83); A plurality of metal strips (85) with convex ends are slidably passed through the surface of the rubber sleeve (83), and a plurality of magnets (86) are attached to one side of the rubber sleeve (83).

6. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: The response component (6) comprises a support frame (61) fixedly connected to the inner wall of the transfer chamber (1); the support frame (61) is fixedly connected to a generator (62); and a fan blade (63) is provided on the surface of the generator (62).

7. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: The surface of the welding machine (20) is provided with a display (24), the welding machine (20) is connected to the welding head assembly (5) and the gas cylinder (21) through an airtight interface (3), and the welding machine (20) is provided with an alarm (25).

8. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: The photoelectric sensor (17) and the gas sensor (12) are communicatively connected to the processor (23), and the automatic interlocking device (22) includes a relay.

9. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: A valve (14) is provided on the lower surface of the transfer chamber (1), and the valve (14) is connected to a bellows (15) for diverting the gas in the transfer chamber (1).

10. The intelligently protected intrinsically safe welding device according to claim 1, characterized in that: A power supply line (13) is provided on one side of the edge power supply (9), and the power supply line (13) is electrically connected to the welding machine (20), and a handle (19) is installed on the surface of the airtight interface (3).

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