A control method of a cable bridge partition welding device

Abstract

The application provides a control method of a cable bridge partition welding device, and relates to the technical field of automatic spot welding of cable bridges. The method comprises the following steps: controlling a spot welding mechanism to move downward to press a second to-be-welded workpiece tightly in an inner groove of a first to-be-welded workpiece by all spot welding heads; obtaining plate information of the first to-be-welded workpiece and the second to-be-welded workpiece, obtaining corresponding welding processes according to the plate information, wherein the plate information at least comprises a material type and a plate thickness at a projection of each spot welding head, and the welding processes at least comprise a welding time and a welding current of each welding point; and controlling conductive components one by one to conduct the corresponding spot welding heads in the welding processes to sequentially weld the first to-be-welded workpiece and the second to-be-welded workpiece at the projection points of each spot welding head in the vertical direction until the spot welding heads all complete the spot welding operation. The application realizes the automatic point-by-point welding of long strip-shaped plates such as cable bridge partitions by conducting the spot welding heads one by one by the conductive components.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic spot welding of cable bridge, in particular to a control method of a cable bridge partition plate welding device. BACKGROUND

[0002] In the installation and use process of the cable bridge, it is often necessary to set a partition plate inside the cable bridge to separate, arrange and fix different types of cables, improve the safety and reliability of cable laying, and the traditional installation method of the cable bridge partition plate mainly adopts bolt connection, riveting and other methods. These installation methods inevitably have problems such as low installation efficiency, low connection strength, easy loosening and the like.

[0003] In the prior art, in order to avoid the above problems, spot welding is also used for connection, but because the length of the cable bridge partition plate is relatively long, the worker needs to extrude the partition plate and the bridge with a large pressure, and then weld each spot welding position in turn until all the spot welding positions in the length direction are completed, which is a huge workload, and the welding effect of each welding position cannot be controlled. SUMMARY

[0004] In view of the above defects or deficiencies in the prior art, the present application aims to provide a control method of a cable bridge partition plate welding device, which is realized based on a cable bridge partition plate welding device. The cable bridge partition plate welding device comprises: a base, the base comprises a base and a fixed support connected with the base, the fixed support and the base have a processing space therebetween, the base has a bearing surface below the fixed support, the bearing surface is provided with a negative electrode plate along the length direction thereof, and the negative electrode plate is provided with a plurality of conductive support blocks for placing first and second to-be-welded workpieces;

[0005] A spot welding mechanism, the spot welding mechanism comprises at least one group of welding gun groups, the welding gun groups comprise a plurality of spot welding heads distributed in sequence along the length direction of the bearing surface, the spot welding heads are arranged in the processing space, and each spot welding head can move in a direction perpendicular to the bearing surface;

[0006] At least one positive electrode plate, the positive electrode plate is fixedly installed on the fixed support and located in the processing space;

[0007] At least one set of conductive mechanisms, each set of the conductive mechanisms is arranged in cooperation with the welding gun, each set of the conductive mechanisms comprises a plurality of flexible conductive sheets corresponding to the spot welding heads respectively, and a driving assembly corresponding to each flexible conductive sheet, the driving assembly is fixed in the machining space, one end of the flexible conductive sheet is connected with a moving end of the corresponding driving assembly, and the other end is electrically connected with the corresponding spot welding head through a conductive block; the flexible conductive sheet has a first state and a second state, in the first state, the flexible conductive sheet abuts against the positive electrode plate to realize electrical connection of the two, in the second state, the flexible conductive sheet is separated from the positive electrode plate; the driving assembly is used to drive the corresponding flexible conductive sheet to switch between the first state and the second state;

[0008] One set of the conductive mechanisms has a corresponding transformer and the positive electrode plate, the transformer provides power for the positive electrode plate and the negative electrode plate; when welding is started, each driving assembly drives the flexible conductive sheet of the corresponding conductive assembly to be in the first state one by one, so as to sequentially weld the first to-be-welded workpiece and the second to-be-welded workpiece at the projection points of each spot welding head in the vertical direction of the spot welding head, and the control method comprises the following steps:

[0009] Controlling the spot welding mechanism to move downward to press the second to-be-welded workpiece in the internal groove of the first to-be-welded workpiece;

[0010] Obtaining plate material information of the first to-be-welded workpiece and the second to-be-welded workpiece, the material of the first to-be-welded workpiece and the second to-be-welded workpiece is the same; according to the plate material information, a corresponding welding process is obtained, the plate material information at least comprises material type and plate thickness at the projection point of each spot welding head, the plate thickness is the total thickness of the first to-be-welded workpiece and the second to-be-welded workpiece in the moving direction of the spot welding head; the welding process at least comprises welding time and welding current of each welding point;

[0011] Controlling the conductive assembly to conduct the corresponding spot welding head according to the welding process to sequentially weld the first to-be-welded workpiece and the second to-be-welded workpiece at the projection points of each spot welding head in the vertical direction of the spot welding head until the spot welding head completes the spot welding operation.

[0012] According to the technical scheme provided by the application, the corresponding welding process is obtained according to the plate material information, and the following steps are specifically included:

[0013] If the plate thickness at the projection point of each spot welding head is the same, a welding process common to all spot welding heads is obtained;

[0014] If the thickness of the plate at the projection of at least two of the spot welding heads is different, a welding process corresponding to each of the spot welding heads is obtained respectively.

[0015] According to the technical scheme provided by the application, after the welding process corresponding to each of the spot welding heads is obtained according to the plate information, before the spot welding operation of the plurality of spot welding heads under the corresponding welding process is sequentially controlled along the length direction of the bearing surface, the following step is further included:

[0016] The real-time power grid voltage in a first preset time period is received.

[0017] The spot welding operation of the plurality of spot welding heads under the corresponding welding process is sequentially controlled along the length direction of the bearing surface, and specifically includes the following steps:

[0018] When all the real-time power grid voltages are in a first preset interval and the real-time power grid voltage change rate in the first preset time period is less than or equal to a first preset threshold, the spot welding operation of the plurality of spot welding heads under the corresponding welding process is sequentially controlled along the length direction of the bearing surface.

[0019] According to the technical scheme provided by the application, after the real-time power grid voltage in a first preset time period is received, the following step is further included:

[0020] When at least one of the real-time power grid voltages is not in the first preset interval or the real-time power grid voltage change rate in the first preset time period is greater than the first preset threshold, a corrected welding process is obtained according to the real-time power grid voltage, and the conductive assembly is controlled one by one to turn on the corresponding spot welding head to sequentially perform the spot welding operation.

[0021] According to the technical scheme provided by the application, the plate information further includes stress distribution of the first and second to-be-welded workpieces; and the spot welding operation of the plurality of spot welding heads under the corresponding welding process is sequentially controlled along the length direction of the bearing surface, and specifically includes the following steps:

[0022] According to the stress distribution, local stresses of each of the spot welding heads at the first and second to-be-welded workpieces are obtained.

[0023] According to each of the local stresses, a welding sequence is obtained, the welding sequence being used to represent the energization timing of each of the spot welding heads, wherein the greater the local stress is, the later the energization timing of the corresponding spot welding head is.

[0024] The plurality of spot welding heads sequentially perform the spot welding operation under the corresponding welding process according to the welding sequence.

[0025] Compared with the prior art, the beneficial effects of the present application are that the present application adopts the design of multiple spot welding heads distributed along the length direction of the bearing surface in sequence, which can simultaneously weld multiple welding points, greatly improving the welding efficiency. Compared with the traditional single spot welding head welding method, a large amount of welding time is saved, and the production efficiency is improved. At the same time, each spot welding head has a corresponding conductive mechanism, which can realize synchronous welding or welding in sequence by sequentially conducting the spot welding heads. In the process of sequentially conducting the spot welding heads, multiple spot welding heads share one transformer for power supply, which can greatly reduce the material cost and has strong flexibility. The welding device can be adjusted and adapted according to different specifications of cable bridge and partition. By adjusting the parameters such as the spacing and movement range of the spot welding heads, the welding needs of cable bridges and partitions of different sizes can be met, and the device has strong versatility and adaptability. At the same time, by obtaining the plate information of the first and second to-be-welded workpieces, the most suitable welding process, including welding time and welding current, can be determined according to different material types and plate thicknesses. In this way, the best welding effect can be ensured for each welding point, and the stability of the welding quality is improved. The spot welding mechanism can press the second to-be-welded workpiece tightly in the internal groove of the first to-be-welded workpiece, ensure the position stability of the workpiece during welding, reduce welding deformation, and further improve the welding quality. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 The structure schematic view inside the cable bridge partition welding device provided by the present application is shown in the figure.

[0027] Figure 2 The structure schematic view of the whole cable bridge partition welding device provided by the present application is shown in the figure.

[0028] Figure 3 The step flow chart of the control method of the cable bridge partition welding device provided by the present application is shown in the figure.

[0029] The text annotations in the figure represent:

[0030] 1, base; 2, fixed support; 3, downward pressing cylinder; 4, negative electrode plate; 5, spot welding head; 6, conductive block; 7, flexible conductive sheet; 8, telescopic cylinder. DETAILED DESCRIPTION

[0031] The present application will be further described in detail below in combination with the drawings and examples. It can be understood that the specific examples described herein are only used to explain the related application, and not to limit the application. In addition, it should be noted that, in order to facilitate description, only the parts related to the application are shown in the drawings.

[0032] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the drawings and in combination with the embodiments.

[0033] Embodiment 1

[0034] As mentioned in the background, in order to solve the problems in the prior art, the present application proposes a cable bridge partition welding device, as shown in Figure 1 , Figure 2 , comprising:

[0035] a base, the base comprises a base 1 and a fixed support 2 connected with the base 1, the fixed support 2 and the base 1 have a processing space therebetween, the base 1 has a bearing surface below the fixed support 2, a negative electrode plate 4 is arranged on the bearing surface along the length direction thereof, and a plurality of conductive support blocks 9 for placing the workpiece to be welded are arranged on the negative electrode plate 4;

[0036] at least one positive electrode plate 11, which is fixedly installed on the fixed support 2 and located in the processing space;

[0037] Specifically, the base 1 is made of a solid metal material, which has sufficient stability and bearing capacity. The fixed support 2 is firmly connected with the base 1 by welding, bolt connection or the like, so as to ensure that no shaking or displacement occurs during welding. The fixed support 2 and the base 1 are both covered with an insulating cover to avoid the risk of electric shock for workers. The height and shape of the fixed support 2 are designed according to actual requirements, so as to ensure that the size of the processing space is appropriate, facilitating the operation and movement of the spot welding head 5. The negative electrode plate 4 is laid on the bearing surface of the base 1 along the length direction thereof. The negative electrode plate 4 can be made of a metal material with good conductivity, such as copper, aluminum or the like. The negative electrode plate 4 is isolated from the base 1 by an insulating material to prevent current leakage.

[0038] Specifically, the positive electrode plate 11 is connected with the positive pole of the transformer. The negative electrode plate 4 should be connected with the negative pole of the transformer. The workpiece to be welded is a cable bridge and a partition, and the partition is placed in the groove body of the cable bridge, so as to weld the cable bridge and the partition together along the length direction thereof by the welding device.

[0039] a spot welding mechanism, the spot welding mechanism comprises at least one group of welding guns, each group of welding guns comprises a plurality of spot welding heads 5 distributed in sequence along the length direction of the bearing surface, the spot welding heads 5 are arranged in the processing space, and each spot welding head 5 can move in a direction perpendicular to the bearing surface; one group of the welding guns has a corresponding transformer to provide power for the spot welding heads in the group of the welding guns;

[0040] A plurality of said spot welding heads 5 are sequentially distributed along the length direction of the bearing surface in the machining space. The number of said spot welding heads 5 can be adjusted according to actual welding requirements. Said spot welding heads 5 can also be moved in the direction perpendicular to the bearing surface through guide rails, sliding blocks and other mechanisms. This moving mode can be achieved by motor drive, hydraulic drive or pneumatic drive, etc. to ensure that the spot welding heads 5 can accurately align the welding points of the workpieces to be welded.

[0041] At least one set of conductive mechanisms, each set of said conductive mechanisms is matched with said welding gun set, each set of said conductive mechanisms includes a plurality of flexible conductive sheets 7 corresponding to said spot welding heads 5, and a driving assembly corresponding to each said flexible conductive sheet 7, said driving assembly is fixed in said machining space, one end of said flexible conductive sheet 7 is connected with the moving end of said driving assembly, and the other end is electrically connected with said spot welding head 5 through a conductive block 6; said flexible conductive sheet 7 has a first state and a second state, in said first state, said flexible conductive sheet 7 abuts against said positive electrode plate 11 to realize the electrical connection of the two, in said second state, said flexible conductive sheet 7 is separated from said positive electrode plate 11; said driving assembly is used to drive the corresponding said flexible conductive sheet 7 to switch between said first state and said second state;

[0042] Specifically, said conductive block 6 can be made of metal materials with good conductive performance such as copper and aluminum. The conductive block 6 and the spot welding head 5 are fixed by welding, bolt connection and other methods to ensure that they will not loosen or displace during welding. The positive electrode plate 11 can be made of the same material as the negative electrode plate 4, and its area and shape should be designed according to actual requirements to ensure good contact and conductive performance with the conductive block 6.

[0043] One set of said conductive mechanisms has a corresponding transformer and positive electrode plate 11, said transformer provides power for said positive electrode plate 11 and negative electrode plate 4; when starting welding, each said driving assembly drives the corresponding said flexible conductive sheet 7 of said conductive assembly to be in said first state one by one, to sequentially weld said workpieces to be welded at each said spot welding head 5 vertical direction projection point by said spot welding head 5.

[0044] Further, the number of said transformers is two: the number of said spot welding heads 5 in this embodiment is six, therefore, one transformer is shared by every three said spot welding heads 5, that is, one said transformer provides power for three adjacent said spot welding heads 5, which can realize time-sharing control, thereby achieving the technical effect of point-by-point welding. Because one transformer may cause the flexible conductive sheet 7 at the edge to have power loss. This is because as the distance from the transformer increases, the current may encounter resistance, inductance and other factors on the transmission path, thereby causing voltage drop, so that the flexible conductive sheet 7 at the edge actually obtains less power.

[0045] However, the problem can be avoided to some extent by using two transformers. When the six spot welding heads 5 are divided into two groups, and each group of three spot welding heads 5 shares one transformer, the distance between each spot welding head 5 and the corresponding transformer is relatively shortened. In this way, the loss of current in the transmission path can be reduced, and the flexible conductive sheet 7 connected to the spot welding head 5 near the edge can also obtain a relatively stable power supply.

[0046] Further, the flexible conductive sheet 7 includes a plurality of flexible conductive strips, and both ends of all the flexible conductive strips in the extension direction are welded to form rigid connection parts.

[0047] Further, the driving assembly is a telescopic air cylinder 8, the fixed end of the telescopic air cylinder 8 is installed on the fixed support 2, and the moving end of the telescopic air cylinder 8 is connected to the rigid connection part at one end of the flexible conductive strip.

[0048] Further, the spot welding mechanism includes two groups of welding gun groups, each group of welding gun groups includes three spot welding heads 5, each transformer provides power for the driving assembly corresponding to three adjacent spot welding heads 5; the negative electrode of the transformer is connected to the negative electrode plate 4; and the positive electrode of the transformer is connected to the positive electrode plate 11.

[0049] Further, the fixed support 2 is provided with a pressing air cylinder 3, the fixed end of the pressing air cylinder 3 is fixed to the fixed support 2, and the moving end of the pressing air cylinder 3 is connected to the conductive mechanism; the pressing air cylinder 3 is used to control the synchronous movement of the plurality of spot welding heads 5 in the direction perpendicular to the bearing surface.

[0050] Specifically, the positive electrode output end of the transformer is connected to the positive electrode plate 11 through a wire, and the negative electrode of the transformer is connected to the negative electrode plate 4 through a wire.

[0051] Specifically, the use process and working principle are described: first, place the cable bridge on the conductive support block 9, then place the partition plate in the cable bridge, when the telescopic cylinder 8 pushes the flexible conductive sheet 7 away from the rigid connection part of one end of the conductive block 6 and the positive electrode plate 11, the power-on state is realized, in the power-on state, the positive output end of the transformer passes through the positive electrode plate 11, the flexible conductive sheet 7 to the conductive block 6, and then the current is transmitted to the spot welding head 5 by the conductive block 6, so that the spot welding head 5 is powered on. At the same time, since the spot welding head 5 is in contact with the cable bridge and the partition plate, and the cable bridge and the partition plate are electrically connected to the negative electrode plate 4 through the conductive support block 9, the negative electrode plate 4 is connected to the negative electrode of the transformer, so that a complete welding current loop is formed, and the partition plate can be welded in the cable bridge. After welding is completed, the telescopic cylinder 8 retracts, so that the rigid connection part of one end of the flexible conductive sheet 7 away from the conductive block 6 is separated from the positive electrode plate 11, the above-mentioned welding current loop is disconnected, and the spot welding head 5 is also powered off.

[0052] Specifically, the conductive block 6 is usually made of materials with good conductive performance, such as copper, silver, etc., to ensure a low-resistance conductive path. The fixing method of the conductive block 6 needs to ensure that it will not loosen or shift during welding, so as to ensure stable conductive performance.

[0053] Specifically, the material of the flexible conductive sheet 7 usually has good flexibility and conductive performance, such as copper foil, conductive rubber, etc. This flexible design enables the conductive sheet to adapt to different spot welding head 5 positions and movement requirements.

[0054] Specifically, when the driving element pushes the flexible conductive sheet 7 away from the negative electrode plate 4 and tightly abuts against the conductive block 6, the power-on state is realized, in the power-on state, the positive output end of the transformer passes through the positive electrode plate to the conductive block 6, and then a conductive path is formed between the flexible conductive sheet 7 and the spot welding head 5, so that the spot welding head 5 is powered on. At the same time, since the spot welding head 5 is in contact with the cable bridge and the partition plate, and the cable bridge and the partition plate are connected to the negative electrode plate 4, a complete welding current loop is formed. After welding is completed, the driving element (telescopic cylinder 8) retracts, so that the flexible conductive sheet 7 is separated from the conductive block 6 away from one end of the negative electrode plate 4, the above-mentioned conductive path is disconnected, and the spot welding head 5 is also powered off.

[0055] Embodiment 2

[0056] On the basis of embodiment 1, the control method of the cable bridge partition plate welding device is proposed, which is realized based on the cable bridge partition plate welding device as described in embodiment 1; please refer to Figure 3As shown, it includes the following steps:

[0057] S1. Control the spot welding mechanism to move down to all the spot welding heads 5 to press the second workpiece to be welded into the inner groove of the first workpiece to be welded;

[0058] Specifically, the cable tray is placed manually on the bearing surface, and the partition is placed inside the inner groove of the cable tray.

[0059] Furthermore, the pressing action in controlling the spot welding mechanism to move down to press all the spot welding heads 5 against the first workpiece to be welded refers to moving all the spot welding heads 5 down so that all the spot welding heads 5 and the bearing surface together clamp the cable tray, thereby fixing the cable tray. In this way, when the energized spot welding head 5 performs spot welding at the corresponding position, the other unenergized spot welding heads 5 can also play a pressing role, ensuring the fit between the cable tray and the partition, and ensuring better welding results.

[0060] S2. Obtain the plate information of the first workpiece to be welded and the second workpiece to be welded, wherein the first workpiece to be welded and the second workpiece to be welded are made of the same material; based on the plate information, obtain the corresponding welding process, wherein the plate information includes at least the material type and the plate thickness at the projection of each spot welding head 5, wherein the plate thickness is the total thickness of the first workpiece to be welded and the second workpiece to be welded in the moving direction of the spot welding head 5; the welding process includes at least the welding time and welding current of each welding point.

[0061] Specifically, equipment such as thickness measuring instruments and material analyzers are used to obtain the plate information of the cable tray and partition, including the material type and the plate thickness at the projection of each spot weld head 5.

[0062] The acquired plate information is input into a database query system (a pre-trained model). The system searches the database based on material type and plate thickness to find matching welding process parameters.

[0063] If a perfect match for the plate material information exists in the database, the corresponding welding time and welding current can be directly obtained. If no perfect match is found, interpolation or approximate matching methods can be used to find the welding process parameters corresponding to the closest plate material information in the database.

[0064] S3. Control the conductive components one by one to conduct the corresponding spot welding head 5 according to the welding process, so as to weld the first workpiece to be welded and the second workpiece to be welded sequentially at the vertical projection point of each spot welding head 5, until all spot welding heads 5 have completed the spot welding operation.

[0065] Specifically, this embodiment has six spot welding heads 5. The first spot welding head 5 is energized in the first state under the action of the control module. After spot welding for a certain period of time, the control module controls its corresponding conductive component to switch to the second state of de-energization. Then, the second spot welding head 5 is energized in the first state under the action of the control module. After spot welding for a certain period of time, it is de-energized. And so on, the third and subsequent spot welding heads 5 perform the same operation in sequence until all spot welding heads 5 have completed the spot welding operation.

[0066] Specifically, this embodiment has two transformers (at this time, there are also two positive electrode plates, and every three spot welding heads 5 share one transformer). Therefore, when performing spot welding operations in sequence, the corresponding transformers need to be started first to provide power to the spot welding heads 5. This can be understood as the first transformer and the second transformer. The first transformer provides power to the first, second, and third spot welding heads, and the second transformer provides power to the fourth, fifth, and sixth spot welding heads. Therefore, when it is necessary to power the first, second, and third spot welding heads, the first transformer is started first. When it is necessary to power the fourth, fifth, and sixth spot welding heads, the second transformer is started first.

[0067] In a preferred embodiment, obtaining the corresponding welding process based on the plate information specifically includes the following steps:

[0068] If the thickness of the plate at the projection of each spot welding head 5 is the same, a welding process common to all spot welding heads 5 is obtained.

[0069] If the thickness of the cable tray partitions is uniform, it indicates that the produced cable tray partitions have good performance. In this way, only one welding process can be obtained, and each of the spot welds 5 can use this welding process.

[0070] If the thickness of the plate is different at the projection of at least two of the spot welding heads 5, the welding process corresponding to each spot welding head 5 is obtained respectively.

[0071] However, there are also cases where the thickness of the cable tray partition is not uniform, that is, some places may be thick and some places may be thin. If the general welding process is used in this case, the thin places will be penetrated and the thick places will not be welded completely. Therefore, if the thickness of the plate at the projection point of a certain spot welding head 5 is different from the thickness of the plate at the projection points of other spot welding heads 5, the corresponding welding process is found according to the corresponding plate thickness. That is, each spot welding head 5 corresponds to a certain welding process.

[0072] This embodiment not only enables the smooth spot welding of cable tray partitions of the same thickness, but also ensures the same spot welding effect in areas of different thicknesses, thereby improving the welding effect and stability.

[0073] In a preferred embodiment, after obtaining the corresponding welding process based on the plate information, and before controlling the plurality of spot welding heads 5 to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process, the following steps are further included:

[0074] Receive the real-time grid voltage within a first preset time period;

[0075] The control of multiple spot welding heads 5 to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process specifically includes the following steps:

[0076] When all the real-time grid voltages are within the first preset range and the rate of change of the real-time grid voltage within the first preset time is less than or equal to the first preset threshold, the multiple spot welding heads 5 are controlled to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process.

[0077] Specifically, the first preset duration is a time range set for collecting and analyzing grid voltage data. Within this time range, the system continuously receives real-time grid voltage information to assess its stability. For example, the first preset duration is 5 seconds, acquiring a voltage value once per second, for a total of 5 real-time grid voltage values. The first preset interval is a voltage range set to determine whether the grid voltage is within a stable range suitable for spot welding. If the real-time grid voltage is within this range, it indicates that the grid voltage is basically stable, which helps ensure spot welding quality. For example, the first preset interval is [220V - 230V]. The first preset threshold is a setting to measure the degree of grid voltage variation. If, within the first preset duration, the rate of change of the grid voltage is less than or equal to this threshold, it indicates that the grid voltage change is relatively gentle and the fluctuations are small, which helps ensure a stable current supply during spot welding. For example, the first preset threshold is set to 5%. If the real-time grid voltage changes from 220V to 221V within the first preset time period (such as the previously assumed 5 seconds), the voltage change rate is calculated to be (221-220) / 220×100%=0.45%. This change rate is less than 5%, so the voltage change rate requirement is met and spot welding can be performed.

[0078] Specifically, since the grid voltage is sometimes stable and sometimes unstable, when the grid voltage is unstable, it has a greater impact on the welding effect. Therefore, this embodiment further specifies that spot welding can be performed using the corresponding welding process found above when the grid voltage is stable and within the normal range, so as to ensure the stability of welding quality.

[0079] Furthermore, after receiving the real-time grid voltage within the first preset time period, the method further includes the following steps:

[0080] When at least one of the real-time grid voltages is not within the first preset range or the rate of change of the real-time grid voltage within the first preset time period is greater than the first preset threshold, a corrected welding process is obtained based on the real-time grid voltage, and the conductive components are controlled one by one to conduct the corresponding spot welding head 5 to perform spot welding operations in sequence using the corrected welding process.

[0081] When the mains voltage is unstable or outside the normal range, it indicates significant voltage fluctuations, which may adversely affect welding quality. For example, excessively high voltage may lead to excessive welding current, easily causing burn-through of the sheet metal or a decline in weld joint quality; excessively low voltage may result in insufficient welding current, failing to form a strong weld joint. In such cases, the welding process calculated based on the sheet metal information needs to be modified. Modification methods may include adjusting the welding current, extending or shortening the welding time, increasing preheating, or post-heat treatment. The specific modification method needs to be determined based on the actual voltage conditions and sheet metal characteristics. This approach ensures welding quality under varying mains voltage conditions.

[0082] The following is an implementation method for extending or shortening the welding time for reference:

[0083] The adjustment coefficient x is obtained by quotient of real-time grid voltage and standard grid voltage. The standard grid voltage is the voltage corresponding to the welding current in the welding process calculated based on the plate information.

[0084] If x is less than 1, the corrected welding time t1 = 1 + (1-x) × t0; if x is greater than 1, the corrected welding time t1 = 1 - (1-x) × t0, where t0 represents the welding time in the welding process calculated based on the plate information, and t1 is the corrected welding time.

[0085] In a preferred embodiment, the plate information further includes the stress distribution of the first workpiece to be welded and the second workpiece to be welded; controlling the plurality of spot welding heads 5 to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process specifically includes the following steps:

[0086] Based on the stress distribution, the local stress of each of the spot welding heads 5 at the first workpiece to be welded and the second workpiece to be welded is obtained;

[0087] Based on the local stresses, a welding sequence is obtained, which is used to characterize the energizing timing of each spot welding head 5. The greater the local stress, the later the energizing timing of the spot welding head 5 is.

[0088] Multiple spot welding heads 5 are controlled to perform spot welding operations sequentially according to the welding sequence under the corresponding welding process.

[0089] Specifically, spot welding can be performed sequentially by energizing the spot welding heads 5 along the length of the bearing surface. However, considering stress issues, if the first spot welding head 5 is located near a weak point such as the edge of the cable tray or partition, the heat generated during welding may cause significant local thermal deformation. During subsequent spot welding, the existing thermal deformation may cause a slight shift in the welding position of the subsequent spot welding heads 5, thus affecting the welding accuracy. Different spot welding sequences will result in different stress distributions on the cable tray and partition during welding. If the sequence is unreasonable, stress may concentrate in certain specific areas, affecting the dimensional accuracy of the welded parts.

[0090] Therefore, this embodiment uses three-dimensional modeling of the combined structure of cable trays and partitions. Professional finite element analysis software can be used, with input parameters such as material properties and geometric dimensions of the cable trays and partitions. Through finite element analysis, the stress distribution under various loads on the structure during and after welding is simulated. Considering factors such as thermal stress and mechanical stress, the areas of stress concentration and stress transmission paths in the structure are determined. This allows for the acquisition of the local stress at the projection of each spot weld joint 5.

[0091] Based on the local stress at the projection of each spot weld head 5, low-stress areas in the structure are preferentially selected as the first welding sites. This reduces stress concentration caused by heat input and local deformation during welding, thus minimizing the impact on the overall structural stability. Optionally, welding can begin at the center of the cable tray or in areas far from critical connections, gradually progressing towards high-stress areas. During this progression, the principle of symmetrical welding can be followed. If the structure is symmetrical, welding can be performed simultaneously at symmetrical locations, or symmetrical parts can be welded sequentially in a symmetrical order. Symmetrical welding ensures more uniform stress distribution during welding, reducing asymmetrical deformation. For example, in this embodiment, the six spot weld heads 5 can be arranged such that the two middle spot weld heads 5 are the first to begin welding, the second spot weld head 5, and so on, spreading outwards sequentially. Thus, the welding sequence along the length of the bearing surface is {6,4,2,1,3,5}, where the numbers indicate the starting point for spot welding.

[0092] In actual production, some cable tray partitions do not have horizontal binding brackets, while others do. For cable tray partitions with binding brackets, after completing the welding of weld points 1-6, shift the entire cable tray to the left in the width direction by about 5cm, so that weld points 2 and 5 can weld to one side of the binding bracket. Then shift the entire cable tray to the right in the width direction by about 10cm, so that weld points 2 and 5 can weld to the other side of the binding bracket.

[0093] The movement of the cable trays needs to be smooth as a whole, which can be achieved by pushing them together with a multi-cylinder system in both directions.

[0094] This solution achieves energy savings in lifting control during the welding process by synchronously pressing down the spot welding head 5. Through transformer group control, it enables individual spot welding, ensuring welding quality at distant weld points while balancing transformer quantity and welding effectiveness. This saves equipment space, resulting in a compact and lightweight design. Cable trays no longer require post-weld processing (carbon dioxide gas shielded welding can cause black spots, necessitating re-galvanizing or painting to improve appearance, incurring additional processing and costs), thus improving production efficiency and reducing production costs.

[0095] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. The above descriptions are only preferred embodiments of the present invention. It should be noted that due to the limitations of textual expression, and the objective existence of infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner; these improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A control method for a cable tray partition welding device, characterized in that, Based on the cable tray partition welding device, the cable tray partition welding device includes: a base, the base including a base (1) and a fixed bracket (2) connected to the base (1), the fixed bracket (2) and the base (1) have a processing space, the base (1) has a bearing surface located below the fixed bracket (2), the bearing surface is provided with a negative electrode plate (4) along its length direction, the negative electrode plate (4) is provided with a plurality of conductive support blocks (9) for placing the first workpiece to be welded and the second workpiece to be welded, the conductive support blocks (9) and the negative electrode plate (4) are electrically connected; A spot welding mechanism, the spot welding mechanism includes at least one set of welding guns, the welding guns include a plurality of spot welding heads (5) distributed sequentially along the length direction of the bearing surface, the spot welding heads (5) are disposed in the processing space, and each spot welding head (5) can move in a direction perpendicular to the bearing surface; At least one positive electrode plate (11) is fixedly mounted on the fixed bracket (2) and located within the processing space; At least one set of conductive mechanisms, each set of conductive mechanisms being configured in conjunction with the welding gun assembly, each set of conductive mechanisms including several flexible conductive sheets (7) corresponding to the spot welding head (5) and a driving component corresponding to each flexible conductive sheet (7), the driving component being fixed within the processing space, one end of the flexible conductive sheet (7) being connected to the moving end of the corresponding driving component, and the other end being electrically connected to the corresponding spot welding head (5) via a conductive block (6); the flexible conductive sheet (7) having a first state and a second state, in the first state, the flexible conductive sheet (7) abutting against the positive electrode plate (11) to achieve electrical connection between the two, in the second state, the flexible conductive sheet (7) being separated from the positive electrode plate (11); the driving component being used to drive the corresponding flexible conductive sheet (7) to switch between the first state and the second state; the flexible conductive sheet (7) including several flexible conductive strips, all of which have two ends welded along the extension direction to form a rigid connection portion; A pressing cylinder (3) is installed on the fixed bracket (2). The fixed end of the pressing cylinder (3) is fixed on the fixed bracket (2), and the moving end of the pressing cylinder (3) is connected to the conductive mechanism. The pressing cylinder (3) is used to control multiple spot welding heads (5) to move synchronously in a direction perpendicular to the bearing surface. A set of the conductive mechanisms has a corresponding transformer and a positive electrode plate (11), and a set of the welding guns has a corresponding transformer. The transformer provides power to the positive electrode plate (11) and the negative electrode plate (4). When welding is started, each of the driving components drives the flexible conductive sheet (7) of the corresponding conductive mechanism to the first state, so as to sequentially conduct the spot welding head (5) to weld the first workpiece to be welded and the second workpiece to be welded at the vertical projection point of each spot welding head (5). The control method includes the following steps: The spot welding mechanism is controlled to move down to all the spot welding heads (5) to press the second workpiece to be welded into the inner groove of the first workpiece to be welded; Obtain the plate information of the first workpiece to be welded and the second workpiece to be welded, wherein the first workpiece to be welded and the second workpiece to be welded are made of the same material; according to the plate information, obtain the corresponding welding process, wherein the plate information includes at least the material type and the plate thickness at the projection of each spot welding head (5), wherein the plate thickness is the total thickness of the first workpiece to be welded and the second workpiece to be welded in the moving direction of the spot welding head (5); wherein the welding process includes at least the welding time and welding current of each welding point; The conductive mechanism is controlled one by one to conduct the corresponding spot welding head (5) according to the welding process, so as to weld the first workpiece to be welded and the second workpiece to be welded sequentially at the vertical projection point of each spot welding head (5) until all spot welding heads (5) have completed the spot welding operation. The plate information also includes the stress distribution of the first workpiece to be welded and the second workpiece to be welded; the control of multiple spot welding heads (5) to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process specifically includes the following steps: Based on the stress distribution, the local stress of each of the spot welding heads (5) at the first workpiece to be welded and the second workpiece to be welded is obtained; Based on the local stresses, a welding sequence is obtained, which is used to characterize the energizing timing of each spot weld head (5). The spot weld head (5) with the greater local stress is located later in the energizing timing. Control multiple spot welding heads (5) to perform spot welding operations sequentially under the corresponding welding process according to the welding sequence.

2. The control method for the cable tray partition welding device according to claim 1, characterized in that, The step of obtaining the corresponding welding process based on the plate information specifically includes the following steps: If the thickness of the plate at the projection of each spot weld head (5) is the same, a common welding process for all spot weld heads (5) is obtained. If the thickness of the plate is different at the projection of at least two of the spot welding heads (5), the welding process corresponding to each spot welding head (5) is obtained respectively.

3. The control method for the cable tray partition welding device according to claim 1, characterized in that, After obtaining the corresponding welding process based on the plate information, before controlling the multiple spot welding heads (5) to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process, the following steps are also included: Receive the real-time grid voltage within a first preset time period; The control of multiple spot welding heads (5) to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process specifically includes the following steps: When all the real-time grid voltages are within the first preset range and the real-time grid voltage change rate within the first preset time is less than or equal to the first preset threshold, the multiple spot welding heads (5) are controlled to perform spot welding operations sequentially along the length direction of the bearing surface under the corresponding welding process.

4. The control method for the cable tray partition welding device according to claim 3, characterized in that, After receiving the real-time grid voltage within the first preset time period, the method further includes the following steps: When at least one of the real-time grid voltages is not within the first preset range or the rate of change of the real-time grid voltage within the first preset time is greater than the first preset threshold, a corrected welding process is obtained based on the real-time grid voltage, and the conductive mechanism is controlled one by one to conduct the corresponding spot welding head (5) to perform spot welding operations in sequence using the corrected welding process.

Images