Robot applied to welding of stator core of high-power wind driven generator and overhead welding method

Abstract

The invention relates to the field of robot overhead welding, in particular to a robot applied to welding of a stator core of a high-power wind driven generator and an overhead welding method. Comprising a whole welding robot workstation, the welding robot workstation is provided with a working platform, two ground rails are arranged on the working platform, a centering device is arranged at the center of the two ground rails, a stator to be welded is arranged on the centering device, a robot system is arranged on the ground rails, and the robot system is provided with a dust removal system. The robot system can slide on the ground rail, a rectangular rack is arranged on the bottom side of the robot system, a movable mechanical arm is arranged on the rack, a welding power source and a water cooling machine are arranged on the side edge of the ground rail, a welding gun is arranged on the mechanical arm, a laser sensor and an electric arc sensor are arranged on the side edge of the welding gun, and the welding gun conducts overhead welding on a stator to be welded. A digital manufacturing technology is adopted for robot overhead welding, the problem that a molten pool is difficult to control in manual overhead welding is solved, the labor intensity of workers is relieved, and the labor cost is reduced.

Description

Technical Field

[0001] The invention relates to the field of robot overhead welding, and in particular to a robot used for welding a stator core of a high-power wind turbine generator and an overhead welding method. Background Art

[0002] With the rapid development of wind power generation technology, the requirements for welding technology in the manufacturing process of high-power wind turbines are getting higher and higher. As the core component of wind turbines, the welding quality of the stator core directly affects the performance and safety of the generator. However, traditional welding methods have problems such as unstable welding quality and low efficiency, and cannot meet the high-precision and high-efficiency welding requirements of high-power wind turbine stator cores.

[0003] At present, manual overhead welding mainly relies on the skills and experience of the operator. The welding operation is completed by maintaining the correct operating posture, adopting appropriate welding parameters and wire feeding methods, and controlling the temperature of the molten pool. However, this method has certain limitations in dealing with complex welding environments and improving welding quality, such as difficulty in controlling the molten droplet transition and large operating errors, which easily lead to welding defects. For the overhead welding part of the stator core welding of high-power wind turbines, manual welding is still mainly used, and the molten pool is difficult to control: because the molten metal falls due to gravity, the shape and size of the molten pool are not easy to control. This may lead to uneven and unstable welds, affecting the welding quality; welding defects are prone to occur: slag inclusions, incomplete penetration, weld nodules, and poor weld formation are prone to occur during overhead welding. These defects will reduce the strength and sealing of the welded joint, and may even lead to welding failure; safety hazards: the molten weld metal is easy to splash and spread, which not only affects the welding quality, but also may cause scalding accidents, posing a threat to the personal safety of the operator; low welding efficiency: compared with welding in other positions, the efficiency of overhead welding is usually lower. This is mainly because overhead welding is more difficult to operate and requires more time and effort to complete.

[0004] Therefore, it is of great practical significance to develop a new type of robotic overhead welding method to solve the problem of difficult molten pool control in manual overhead welding. Summary of the invention

[0005] The present application provides a robot and an overhead welding method for welding the stator core of a high-power wind turbine generator, which solves the problem of difficult molten pool control in manual overhead welding. According to a predetermined path, the arc starting distance between the welding gun and the groove is controlled, and the position to be welded is accurately located by a laser sensor, and then the weld deviation is corrected by an arc sensor, thereby greatly reducing the occurrence of welding defects such as slag inclusion, incomplete penetration, and weld nodules.

[0006] The following technical solutions are adopted: A robot and overhead welding method for welding the stator core of a high-power wind turbine generator. A robot overhead welding method for welding the stator core of a high-power wind turbine generator. Step A: The welding robot is precisely programmed to move the robot system along a predetermined path, while recording the movement trajectory and welding parameters. The arc sensor continuously compensates for weld deviation to ensure that the robot can accurately move along the preset trajectory during the welding process.

[0007] Step B: Fix and install the stator to be welded in the center position.

[0008] Step C: Start the robot system and control the robot arm to perform overhead welding on the stator to be welded by setting a program. During this period, high-precision laser sensors and arc sensors are used to monitor the welding process in real time, and the welding parameters are dynamically adjusted according to the feedback data to ensure the stability of the welding quality and the accuracy of the weld.

[0009] Step D: Perform a base weld on the innermost part of the groove between the stator core cover plate and the reinforcement rib thereon, and perform the first filling weld, the second filling weld, the third filling weld, the fourth filling weld and the cover weld on the basis of the base weld to complete the entire overhead welding operation.

[0010] A robot used for welding the stator core of a high-power wind turbine generator comprises a whole welding robot workstation, wherein the welding robot workstation is provided with a working platform, and two ground rails are provided on the working platform, and the ground rails are correspondingly provided on both sides of the working platform, and a centering device is provided at the center of the two ground rails, and a stator to be welded is provided on the centering device, and a robot system is provided on the ground rails, and the robot system is provided with a dust removal system, and the robot system can slide on the ground rails, and the bottom side of the robot system is a rectangular frame, and a movable mechanical arm is provided on the frame, and a welding power supply and a water cooler are provided on the side of the ground rail, and a welding gun is provided on the mechanical arm, and a laser sensor and an arc sensor are provided on the side of the welding gun, and the welding gun performs overhead welding on the stator to be welded.

[0011] Optionally, the robotic arm on the robot system is a rotating C-frame, and the rotating C-frame is provided with a main arm frame, a rotating shaft, a first connecting shaft, a second connecting shaft and a third connecting shaft.

[0012] Optionally, a laser sensor is used to locate the welding position when welding the stator to be welded, and an arc sensor is used to detect weld deviation during the welding process.

[0013] Optionally, the dust removal system includes a control box and a dust removal bucket, and the control box and the dust removal bucket are arranged on both sides of the robot system.

[0014] Optionally, a groove to be overhead welded is provided between the stator core cover plate and the reinforcing ribs on the stator to be welded.

[0015] Optionally, a base weld is first performed on the groove, and a first filling weld, a second filling weld, a third filling weld, a fourth filling weld and a cap weld are performed on the base weld.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. Robot overhead welding ensures accurate positioning of welding points through high-precision trajectory planning and motion control. At the same time, the continuous and stable working rhythm also greatly improves welding efficiency.

[0017] 2. Robot overhead welding uses uniform process parameters to effectively eliminate quality fluctuations caused by human factors. Laser sensor positioning and arc sensor compensation for weld deviation ensure uniformity and stability of weld quality. It can ensure the flatness of the weld surface and improve the aesthetics and functionality of the weld.

[0018] 3. Robotic automated welding significantly reduces the labor intensity of workers and reduces the demand for skilled welders, thereby reducing labor costs.

[0019] 4. Enhance safety and reduce human errors. Robotic overhead welding reduces direct operation by personnel, improves workplace safety, and effectively avoids human operation errors. Robotic overhead welding can achieve 24-hour uninterrupted automated production, greatly improving welding efficiency. Compared with manual overhead welding, robotic overhead welding can complete more welding tasks in a shorter time.

[0020] 5. Flexibility and scalability. The robot overhead welding method can be quickly adjusted to adapt to products of different specifications through programming, showing higher flexibility and production expansion capabilities than manual welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be discussed below. Obviously, the technical solutions described in conjunction with the drawings are only some embodiments of the present invention. For ordinary technicians in this field, other embodiments and their drawings can be obtained based on the embodiments shown in these drawings without paying creative work.

[0022] Figure 1 It is a three-dimensional diagram of the overall structure of the welding robot workstation of the present invention.

[0023] Figure 2 It is a front view of the overall structure of the welding robot workstation of the present invention.

[0024] Figure 3 It is a left view of the overall structure diagram of the welding robot workstation of the present invention.

[0025] Figure 4 It is a schematic diagram of the structure of the mechanical arm of the robot system of the welding robot workstation of the present invention.

[0026] Figure 5 It is a schematic diagram of the welding gun structure of the welding robot workstation of the present invention.

[0027] Figure 6 It is the overhead welding position and welding sequence diagram of the present invention.

[0028] Figure 7 It is a schematic diagram of the stator structure to be welded according to the present invention.

[0029] In the figure: 1-stator to be welded, 2-dust removal system, 3-robot system, 4-ground rail, 5-centering device, 6-welding power supply, 7-water cooler, 8-rotating C-frame, 9-base weld, 10-first filling weld, 11-second filling weld, 12-third filling weld, 13-fourth filling weld, 14-cap weld, 15-groove, 16-welding gun, 17-rotating shaft, 18-first connecting shaft, 19-second connecting shaft, 20-third connecting shaft, 21-welding control box. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions of various embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0032] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0033] The embodiments of the present invention provide a robot and an overhead welding method for welding a stator core of a high-power wind turbine generator.

[0034] A robot used for welding the stator core of a high-power wind turbine generator comprises an entire welding robot workstation. The entire welding robot workstation is provided with a working platform. Two ground rails 4 are provided on the working platform. The ground rails 4 are correspondingly provided on two sides of the working platform. A centering device 5 is provided at the center of the two ground rails 4. A stator 1 to be welded is provided on the centering device 5. The stator 1 to be welded is aligned with the clamping position on the centering device 5. The centering device 5 also plays a role in fixing the stator 1 to be welded, aligning the welding line on the stator 1 to be welded with the centering device 5, and accurately positioning the position of the stator 1 to be welded. A robot system 3 is arranged on the ground rail 4. The robot system 3 is provided with a dust removal system 2. The dust removal system 2 includes a control box and a dust removal bucket. The control box and the dust removal bucket are arranged on both sides of the robot system 3. The robot system 3 can slide on the ground rail 4. The bottom side of the robot system 3 is a rectangular frame. A control center processor is arranged in the frame. A movable robotic arm is arranged on the frame. A welding power supply 6 and a water cooler 7 are arranged on the sides of the two ground rails 4. The welding power supply 7 provides welding current for the robot system 3, and the water cooler 7 cools down the robot system 3.

[0035] The robot arm on the robot system 3 is a rotating C-shaped frame 8, and the rotating C-shaped frame 8 is provided with a main arm frame, a rotating shaft 17, a first connecting shaft 18, a second connecting shaft 19 and a third connecting shaft 20. The main arm frame is arranged on the frame of the robot system 3, and the main arm frame is provided with a connecting rotating shaft 17, and the rotating shaft 17 is connected with the first connecting shaft 18, one end of the first connecting shaft 18 is arranged on the rotating shaft 17, and the other end is provided with a second connecting shaft 19, and the second connecting shaft 19 is provided with a third connecting shaft 20, and the second connecting shaft 19 can rotate on the first connecting shaft 18, and the third connecting shaft 18 can rotate on the second connecting shaft 19; a welding gun 16 is arranged at the top end of the third connecting shaft 20, and the welding gun 16 can move freely, and a laser sensor and an arc sensor are arranged at the side of the welding gun 16, and the laser sensor can play a role in finding and locating the welding position when welding the stator 1 to be welded, and the arc sensor detects the weld deviation during the welding process. The laser sensor transmits the position distance relationship with the stator 1 to be welded to the robot system 3 through laser positioning. The system edits and processes the obtained information, controls the position relationship of the rotating C-frame 8, and accurately positions the welding gun 16 to the stator to be welded by adjusting the first connecting shaft 18, the second connecting shaft 19 and the third connecting shaft 20 for welding. During the welding process, the arc sensor transmits the position relationship information of the weld to the robot system 3. The system controls the current size according to the feedback information to perform welding repair on the weld deviation through the welding gun 16, realizing the technology of high-quality welding. The welding speed of the stator 1 to be welded can be accelerated by the robot systems 3 on both sides. A welding control box 21 is set on the working platform, and the welding control box 21 can control the welding current size of the welding gun 16 to achieve overhead welding.

[0036] like Figure 6 As shown, a groove 15 to be welded overhead is provided between the stator core cover plate and the reinforcing rib thereon on the stator 1 to be welded. During overhead welding, the welding gun 16 is aimed at the opening of the groove 15, and a base weld 9 is first performed at the innermost part of the groove 15. On the basis of the base weld 9, a first filling weld 10, a second filling weld 11, a third filling weld 12, a fourth filling weld 13 and a cover weld 14 are performed to complete the entire overhead welding operation.

[0037] When performing overhead welding on the stator for the first time, it is necessary to consider the effect of gravity on metal melting, teach and reproduce the motion trajectory of the welding robot, so that it moves along the predetermined path, and record these motion trajectories and welding parameters. The arc sensor continuously compensates for the weld deviation, and then continuously optimizes the welding trajectory and welding parameters through the evaluation of the weld quality. The laser sensor then locates the arc starting position of other overhead welding grooves on the stator core, thereby realizing fully automatic overhead welding of the stator core. In terms of setting the welding process parameters, the key parameters such as welding current, voltage, and welding speed are accurately set according to the material and thickness of the stator core to ensure the quality of the overhead welding groove weld.

[0038] The use of the robot for welding the stator core of a high-power wind turbine is as follows: Step A: Precisely program the welding robot, move the robot system 3 along a predetermined path, and record the movement trajectory and welding parameters. The arc sensor continuously compensates for the weld deviation to ensure that the robot can accurately move along the preset trajectory during the welding process.

[0039] Step B: The stator 1 to be welded is fixedly installed in the center position.

[0040] Step C: Start the robot system 3 and control the robot arm to perform overhead welding on the stator 1 to be welded by setting a program. During this period, high-precision laser sensors and arc sensors are used to monitor the welding process in real time, and welding parameters are dynamically adjusted according to feedback data to ensure the stability of welding quality and the accuracy of the weld.

[0041] Step D: Perform a base weld 9 on the innermost part of the groove 15 between the stator core cover plate and the reinforcement rib thereon, and perform a first filling weld 10, a second filling weld 11, a third filling weld 12, a fourth filling weld 13 and a cover weld 14 on the basis of the base weld 9 to complete the entire overhead welding operation.

[0042] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive from any point of view. The scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0043] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A robot overhead welding method for welding the stator core of a high-power wind turbine generator, characterized in that: The following steps are involved: Step A: Precisely program the welding robot, move the robot system (3) along a predetermined path, and record the movement trajectory and welding parameters. The arc sensor continuously compensates for the weld deviation to ensure that the robot can accurately move along the preset trajectory during the welding process; Step B: The stator to be welded (1) is fixedly installed and set in a centering position; Step C: Start the robot system (3) and control the robot arm to perform overhead welding on the stator (1) to be welded by setting a program. During the process, a high-precision laser sensor and an arc sensor are used to monitor the welding process in real time, and the welding parameters are dynamically adjusted according to the feedback data to ensure the stability of the welding quality and the accuracy of the weld. Step D: performing a base weld (9) on the innermost part of the groove (15) between the stator core cover plate and the reinforcing rib thereon, and performing a first filler weld (10), a second filler weld (11), a third filler weld (12), a fourth filler weld (13) and a cover weld (14) on the basis of the base weld (9), thereby completing the entire overhead welding operation.

2. A robot used for welding the stator core of a high-power wind turbine generator, characterized in that: The welding robot workstation comprises a whole welding robot workstation, wherein the welding robot workstation is provided with a working platform, two ground rails (4) are provided on the working platform, the ground rails (4) are provided on both sides of the working platform respectively, a centering device (5) is provided at the center of the two ground rails (4), a stator (1) to be welded is provided on the centering device (5), a robot system (3) is provided on the ground rail (4), the robot system (3) is provided with a dust removal system (2), the robot system (3) can slide on the ground rail (4), the bottom side of the robot system (3) is a rectangular frame, a movable mechanical arm is provided on the frame, a welding power source (6) and a water cooler (7) are provided on the side of the ground rail (4), a welding gun (16) is provided on the mechanical arm, a laser sensor and an arc sensor are provided on the side of the welding gun (16), and the welding gun (16) performs overhead welding on the stator (1) to be welded.

3. The robot used for welding the stator core of a high-power wind turbine generator according to claim 2, characterized in that: The mechanical arm on the robot system (3) is a rotating C-shaped frame (8), and the rotating C-shaped frame (8) is provided with a main arm frame, a rotating shaft (17), a first connecting shaft (18), a second connecting shaft (19) and a third connecting shaft (20).

4. The robot used for welding the stator core of a high-power wind turbine according to claim 2, characterized in that: The laser sensor is used to locate the welding position when welding the stator (1) to be welded, and the arc sensor is used to detect the weld deviation during the welding process.

5. The robot used for welding the stator core of a high-power wind turbine according to claim 2, characterized in that: The dust removal system (2) comprises a control box and a dust removal bucket, and the control box and the dust removal bucket are arranged on both sides of the robot system (3).

6. The robot used for welding the stator core of a high-power wind turbine generator according to claim 2, characterized in that: A groove (15) to be welded is provided between the stator core cover plate and the reinforcing ribs on the stator to be welded (1).

7. The robot used for welding the stator core of a high-power wind turbine according to claim 6, characterized in that: A base weld (9) is firstly performed on the groove (15), and a first filler weld (10), a second filler weld (11), a third filler weld (12), a fourth filler weld (13) and a cap weld (14) are performed on the base weld (9).

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