Large-scale panel welding method and large-scale panel welding production line

Abstract

The invention discloses a large-scale panel welding method and a large-scale panel welding production line, comprising the following steps: S1, panel spot welding, at an assembly station, pre-cut dispersed panels are assembled on a platform and fixed by spot welding, S2, the transmission of panels to be welded is aligned with the weld seam, the splicing station, the welding station and the disassembly station are connected in series through a transmission device, S3, panel welding, the gantry can move forward and backward along the direction of the production line, and the hanger on the gantry can drive the welding trolley track to move left and right, S4, fixture disassembly, the chain transmission device transmits the welded panel to the disassembly station, and the fixtures clamped around the panel are manually disassembled; the invention solves the problem that the current equipment lacks an assembly line, resulting in a large difference in processing time for each step, and in batch overall processing, the overall time is the sum of the longest processing time of all steps and each step.

Description

Technical Field

[0001] The invention relates to the technical field of welding equipment, in particular to a large-scale panel welding method and a large-scale panel welding production line. Background Art

[0002] In today's manufacturing industry, improving production efficiency, ensuring product quality and reducing production costs have always been the core goals pursued by enterprises. With the continuous development of industrial technology, the demand for large-scale panel welding is increasing.

[0003] Traditional large-scale panel welding usually relies on manual operation, which is not only labor-intensive but also inefficient. Workers need to work for a long time in a harsh environment, and the welding quality is difficult to guarantee. It is easily affected by human factors, such as differences in welding technology levels and unstable working conditions. At the same time, traditional welding methods often have problems such as low welding accuracy and uneven welds when facing large panels, which not only affects the appearance of the product, but is also likely to reduce the structural strength and service life of the product.

[0004] In addition, the traditional process lacks effective automated control in the production process, making it difficult to achieve continuous production, resulting in a long production cycle and being unable to meet the market's demand for rapid delivery of large panels. Moreover, due to the lack of a unified assembly line, there are also many problems in the production process, such as processing time coordination and process connection, which increases the management costs of the company.

[0005] Especially in the production of large-scale panel welding, it needs to be divided into multiple steps, processes and equipment. However, due to the lack of an assembly line, the current equipment has a large difference in the processing time of each step. In the overall batch processing, the overall time is the sum of all steps and the longest processing time of each step. Therefore, there is an urgent need for a large-scale panel welding method and a large-scale panel welding assembly line to solve these problems, improve the efficiency and quality of large-scale panel welding, reduce production costs, and meet market demand. Summary of the invention

[0006] The present invention aims to solve the problems of the prior art welding equipment, which lacks a unified assembly line operation and thus causes problems in the production process such as the coordination of processing time and the connection of working procedures.

[0007] The technical solution of the present invention is achieved in this way:

[0008] A large-scale panel welding method comprises the following steps:

[0009] S1, panel spot welding. At the assembly station, the pre-cut dispersed plates are assembled on the platform and fixed by spot welding to obtain a large panel that meets the welding requirements. Four clamps are detachably clamped around the panel, and the outer edges of the four clamps are respectively parallel to the transverse weld and the longitudinal weld to ensure that each weld on the panel can be adjusted to the welding position at the welding station. After the clamps are clamped, the panel to be welded is obtained. The bull's eye wheel array under the splicing station rises and passes through the holes on the splicing platform that are distributed in the same manner as the bull's eye wheel array, and the panel is lifted up, and the panel is separated from the splicing platform, so that the panel to be welded can be transferred to the next station;

[0010] S2, the transmission of the panels to be welded is aligned with the weld seam. The splicing station, welding station and disassembly station are connected in series through a transmission device. The chain transmission device buckles the outer edge of the fixture to transmit the panel to the welding station. If the panel tilts in the horizontal direction during the transmission process, the two chain buckles buckled on the edge of the fixture can correct the panel through differential transmission. At the welding station, through the mutual cooperation of the chain transmission device, any horizontal weld seam and longitudinal weld seam on the panel can be aligned with the welding position on the welding station, and at the same time, it is ensured that there is no obstacle under the panel to hinder the movement of the back-up trolley; the welded panel is transmitted to the disassembly station by the chain transmission device on the disassembly station, and the fixtures clamped around the panel are disassembled and transmitted out of the assembly line;

[0011] S3, panel welding, the gantry can move forward and backward along the direction of the assembly line, the hanger on the gantry can drive the welding trolley track to move left and right, the welding trolley can move along the welding trolley track, the conveying device of the welding station moves the panel, and the transverse weld on the panel is moved to the welding position, or the gantry moves the welding trolley track to the transverse weld position of the panel, and the welding trolley and the back-up trolley cooperate with each other to achieve the welding of the transverse weld of the panel. After the transverse weld is completed, the welding trolley track is rotated 90 degrees by the rotating device, and the longitudinal weld on the panel is welded in the same way as the transverse weld.

[0012] S4, fixture disassembly, the chain conveyor conveys the welded panel to the disassembly station, the fixtures installed around the panel are manually disassembled, and the fixtures are transported to the splicing station by the overhead crane to prepare for the next cycle, and the welded panel is conveyed out of the assembly line;

[0013] A large-scale panel welding production line includes a gantry with a movable track and an array of bull's eye wheels that are arranged on the ground and are at the same height and evenly distributed, and also includes an assembly station, a welding station and a disassembly station; a sliding track is fixedly installed on the crossbeam on the gantry, a lifting device is installed in the sliding track and slides on the sliding track, an L-shaped hanger is fixedly installed on the lifting device, the L-shaped hanger is fixedly connected to the welding track, and a welding gun is installed on the welding track.

[0014] There is a gap in the middle of the bull's eye wheel array, and the gap is the activity area of ​​the back-protection trolley, and the back-protection trolley moves in the gap according to the moving track of the welding gun.

[0015] The back-protection trolley is composed of a body with a motor, a power source and wheels, a lifter fixed on the body and an air outlet pipe fixed on the lifter, and the air outlet pipe is connected to a gas tank arranged at a welding station.

[0016] The present invention has the following advantages compared with the prior art:

[0017] The present invention successfully solves the problem of large processing time differences in each step caused by the lack of assembly lines in current equipment. In batch overall processing, the overall time of the traditional method is the sum of the longest processing time of all steps, and the assembly line design of the present invention greatly optimizes this situation. The various workstations are closely coordinated with minimal time differences, achieving efficient continuous production. From the assembly station to the welding station to the disassembly station, each link is seamlessly connected, greatly shortening the overall production time.

[0018] The various workstations of the present invention cooperate closely and accurately, collaborate efficiently, and have extremely small time differences. After the fixture is clamped at the assembly station, the panel to be welded is obtained, and the bull's eye wheel array below the splicing station rises, passes through the holes on the splicing platform that are consistent with the distribution of the bull's eye wheel array, and lifts up the panel, so that the panel can be quickly separated from the splicing platform and prepared for transmission to the next workstation. This process is efficient and stable, and there is almost no time delay.

[0019] The splicing station, welding station and disassembly station are connected in series through the conveyor device, forming an efficient production process. The chain conveyor device can accurately buckle the edge of the fixture and smoothly transfer the panel to the welding station. During the transmission process, the chain buckle of the differential drive can correct the tilt of the panel in time to ensure the accurate position of the panel. At the welding station, through the mutual cooperation of the chain conveyor device, any horizontal weld and longitudinal weld on the panel can be quickly aligned with the welding position, while ensuring that the movement of the back-up trolley is not hindered. This process shows a high degree of automation and precision, greatly improving production efficiency.

[0020] The welding stations also demonstrate efficient coordination. The bull's eye wheels arranged in an array on the ground are at the same height as other stations, ensuring smooth entry of welded parts. The conveyor is arranged front, back, left, and right with the welding station as the center. With the push plate and AGV back-up trolley, the weld can be quickly aligned with the center of the bull's eye wheel array aisle. The operations of each link are closely connected, and the time difference of working time is extremely small, making the entire welding process smooth and efficient.

[0021] During the first welding, the transition between each step is natural and rapid, from the weldment entering the welding station to the chain buckle centering the weld, to the back-up trolley in place and the welding gantry starting. The front, back, left and right chain buckles cooperate with each other to ensure the high efficiency of the weld centering and greatly reduce time waste. The back-up trolley and the welding trolley start and stop at the same time, and the two cooperate well, further improving the welding efficiency.

[0022] In the continuous welding process, four plates can be spliced ​​at the same time, and the chain buckle on the conveyor station pushes the spot-welded plates, making the whole process seamless. The time difference between each station is controlled within a very small range, achieving the purpose of efficient continuous production. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of a large-scale panel welding method of the present invention.

[0024] Figure 2 It is a schematic diagram of a large-scale panel welding production line of the present invention.

[0025] Figure 3 It is a schematic diagram of welding stations of a large-scale panel welding production line of the present invention.

[0026] Figure 4 It is a schematic diagram of an AGV back-protection trolley working in conjunction with a welding station of a large-scale panel welding production line of the present invention.

[0027] Figure 5 yes Figure 4 A partial enlarged view of part A.

[0028] Figure 6 It is a schematic diagram of the structure of the AGV back-protection trolley of the present invention.

[0029] Figure 7 yes Figure 3 An enlarged view of the welding station of the present invention.

[0030] Figure 8 It is a chain buckle for a large-scale panel welding production line of the present invention.

[0031] In the figure, 1-gantry; 2-bull's eye wheel array; 3-assembly station; 4-disassembly station; 5-back-protection trolley; 6-L-shaped hanger; 7-lifting device; 8-welding track; 9-welding gun; 10-jigsaw; 11-sliding track; 12-chain buckle.

[0032] 501-body; 502-lifter; 503-exhaust pipe; 504-motor. DETAILED DESCRIPTION

[0033] The specific implementation methods, features and effects of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments. Example 1

[0034] like Figure 1 As shown, the present invention provides a large-scale panel welding method, comprising the following steps:

[0035] S1, panel spot welding. At the assembly station, the pre-cut dispersed plates are assembled on the platform and fixed by spot welding to obtain a large panel that meets the welding requirements. Four clamps are detachably clamped around the panel, and the outer edges of the four clamps are respectively parallel to the transverse weld and the longitudinal weld to ensure that each weld on the panel can be adjusted to the welding position at the welding station. After the clamps are clamped, the panel to be welded is obtained. The bull's eye wheel array under the splicing station rises and passes through the holes on the splicing platform that are distributed in the same manner as the bull's eye wheel array, and the panel is lifted up, and the panel is separated from the splicing platform, so that the panel to be welded can be transferred to the next station;

[0036] S2, the transmission of the panels to be welded is aligned with the weld seam. The splicing station, welding station and disassembly station are connected in series through a transmission device. The chain transmission device buckles the outer edge of the fixture to transmit the panel to the welding station. If the panel tilts in the horizontal direction during the transmission process, the two chain buckles 12 buckled on the edge of the fixture can correct the panel through differential transmission. At the welding station, through the mutual cooperation of the chain transmission device, any transverse weld seam and longitudinal weld seam on the panel can be aligned with the welding position on the welding station, and at the same time, it is ensured that there is no obstacle under the panel to hinder the movement of the back-protection trolley; the welded panel is transmitted to the disassembly station by the chain transmission device on the disassembly station, and the fixtures clamped around the panel are disassembled and transmitted out of the assembly line;

[0037] S3, panel welding, the gantry can move forward and backward along the direction of the assembly line, the hanger on the gantry can drive the welding trolley track to move left and right, the welding trolley can move along the welding trolley track, the conveying device of the welding station moves the panel, and the transverse weld on the panel is moved to the welding position, or the gantry moves the welding trolley track to the transverse weld position of the panel, and the welding trolley and the back-up trolley cooperate with each other to achieve the welding of the transverse weld of the panel. After the transverse weld is completed, the welding trolley track is rotated 90 degrees by the rotating device, and the longitudinal weld on the panel is welded in the same way as the transverse weld.

[0038] S4, fixture disassembly, the chain conveyor conveys the welded panel to the disassembly station, the fixtures installed around the panel are manually disassembled, and the fixtures are transported to the splicing station by the overhead crane to prepare for the next cycle, and the welded panel is conveyed out of the assembly line.

[0039] A sliding track is fixedly installed on the crossbeam on the gantry 1 , the lifting device is installed in the sliding track and slides on the sliding track, and the L-shaped hanger is fixedly installed on the lifting device 7 .

[0040] A rotating device is installed under the lifting device 7, which can rotate the hanger to weld the transverse and longitudinal welds. After welding all the transverse seams, the lifting device 7 lifts the hanger, and after the rotating device rotates 90 degrees, the lifting device 7 drops the hanger to start welding the longitudinal seams. The rotated hanger can move forward, backward, left and right under the action of the gantry, so that the welding trolley can traverse any weld of the puzzle plate 10.

[0041] In S3, during continuous welding, in order to improve efficiency, four plates can be spliced ​​at the assembly station 3 at the same time, and the spliced ​​plates are prepared at the transfer station. The chain buckle 12 on the transfer station pushes the spot-welded plate, pushes the forward push plate, and then pushes the plate being welded, so that its weld is aligned with the center of the array bull's eye wheel.

[0042] Preferably, in S3, the welding stations are arranged in an array on the ground with bull's eye wheels that are at the same height as the splicing stations, a conveying device is installed between the bull's eye wheel arrays 2, and there are gaps in the bull's eye wheel arrays 2, which serve as the movement space for the AGV back-up trolley 5.

[0043] More preferably, in said S3, the following steps are also included:

[0044] S21, weld alignment, push the panel 10 by the push plate, the front and rear push plates complete the alignment of the transverse weld, the left and right push plates are responsible for the alignment of the longitudinal weld, and the welds of the panel 10 need to be moved to the center of the bull's eye wheel array 2 so as to cooperate with the back-protection trolley 5 for welding. After the welds are aligned, they are integrated and the weld placement signal is sent to the control unit;

[0045] S22, the back-protecting trolley 5 is reset, the back-protecting trolley 5 returns to the starting point, and sends a positioning signal to the control unit.

[0046] Preferably, in S4, when the panel 10 is welded, the back-protection trolley 5 moves along the weld, and argon gas is continuously passed under the panel 10 to protect the weld.

[0047] More preferably, the back-protection trolley 5 moves at the same speed as the welding gun 9 at the welding station.

[0048] More preferably, in S3, according to welding requirements, the gantry can move forward or backward along the flow direction of the assembly line, and the L-shaped hanger can also be on the gantry beam, and the hanger follows the lifting device and moves left and right on the track of the gantry beam.

[0049] Preferably, during the transfer and dragging process of the panel 10, when tilting and offset occur, making the weld of the panel 10 unable to be parallel to the aisle of the bull's eye wheel array 2, two chain buckles 12 hooked on the panel 10 apply thrust to the panel 10 at different speeds, and at the same time, two chain buckles 12 on the opposite sides are stationary in the forward direction of the panel 10 to correct the panel 10. In the correction of the panel 10, left-tilt correction and right-tilt correction are included, and the ratio of the differential speed can be adjusted according to the size of the tilt angle.

[0050] like Figure 2-Figure 6 As shown, a large-scale panel welding production line includes a gantry 1 with a movable track and a bull's eye wheel array 2 which is arranged on the ground and has a consistent height and is evenly distributed, and also includes an assembly station 3, a welding station and a disassembly station 4; on the crossbeam on the gantry, a sliding track is fixedly installed, a lifting device is installed in the sliding track and slides on the sliding track, an L-shaped hanger is fixedly installed on the lifting device, the L-shaped hanger is fixedly connected to the welding track, and a welding gun is installed on the welding track.

[0051] There is a gap in the middle of the bull's eye wheel array 2, and the gap is the activity area of ​​the back-protection trolley 5. The back-protection trolley 5 moves in the gap according to the movement trajectory of the welding gun 9.

[0052] The back-protection trolley 5 is composed of a body 501 equipped with a motor 504, a power source and wheels, a lifter 502 fixed on the body 501 and an air outlet pipe 503 fixed on the lifter 502, and the air outlet pipe 503 is connected to a gas tank arranged at the welding station.

[0053] In this embodiment, the following advantages are also achieved:

[0054] 1. Optimize the assembly of the panels 10. The assembled bottom plate is divided into four independent pieces. Several panels 10 can be spot welded at the same time, which greatly increases the number of panels 10 processed at the same time and improves the spot welding efficiency. The worm gear lifting device 7 and the motor 504 drive the transmission shaft to control the lifting, making the spot welding operation and the welding plate transfer process faster and more stable, reducing the operation time.

[0055] 2. Quickly align and level the panel 10, and ensure that the height of the bull's eye wheels at the transmission alignment station and the welding station are consistent, ensuring that the panel 10 can be smoothly transferred between different stations, avoiding jams and adjustment time caused by height differences, and improving transmission efficiency.

[0056] 3. Fast welding. The conveying device of the welding station is arranged front, back, left and right with the welding station as the center. With the design of the navigation bar and push plate of the AGV back-protection trolley 5, the weld can be quickly and accurately aligned with the center of the aisle of the bull's eye wheel array 2, which reduces the time for weld centering and improves welding efficiency.

[0057] 4. The welding gun 9 has a wide range of movement, and the gantry can move forward or backward along the flow direction of the assembly line, and can also move left and right on the gantry 1, so that the welding trolley can quickly reach every position of the puzzle plate 10, reducing the moving time of the welding trolley.

[0058] 5. Automatically adjust the panels 10. The rotary device under the lifting device 7 can rotate the hanger to facilitate the welding of transverse and longitudinal welds. There is no need to manually adjust the position of the panels 10, which improves the continuity and efficiency of welding.

[0059] 6. The panel 10 is easy to move, and the chain buckle 12 can automatically rotate from the bottom to the top and move continuously. After the welding plate is buckled, it can be automatically moved to the transmission alignment station, reducing the time and labor intensity of manual handling.

[0060] 7. Automated weld centering: At the welding station, the chain conveyor with the chain buckle 12 hooks the front push plate to move, so that the weld is quickly moved to the center of the bull's eye wheel array 2, realizing the automated weld centering operation.

[0061] 8. Rapid correction: two chain buckles 12 are used to apply thrust to the puzzle board 10 at different speeds. At the same time, two chain buckles 12 on opposite sides are stationary and block the forward direction of the puzzle board 10 for correction. The correction operation can be completed with one button on the controller without manual intervention, which improves the correction efficiency. Example 2

[0062] In this embodiment, in order to realize the simultaneous splicing of multiple boards:

[0063] During continuous welding, four plates can be spliced ​​at the same time, and the spliced ​​plates are prepared at the transfer station, which greatly shortens the splicing time and improves the overall production efficiency.

[0064] The chain buckle 12 on the transfer station pushes the spot-welded plate, pushes the forward push plate, and then pushes the plate being welded, so that the weld is aligned with the center of the array bull's eye wheel, thereby realizing a continuous welding process and reducing waiting time. Example 3

[0065] In this embodiment, in order to realize R fillet welding:

[0066] A section of curved track is assembled on the straight track. The welding carriage can automatically weld the R fillet weld under the guidance of the laser sensor. The module of the welding gun 9 actuator will perform corresponding expansion and contraction changes to compensate for the change of the R angle, thereby improving the welding efficiency of the R fillet weld.

[0067] When it is necessary to weld an R fillet weld, a curved track is assembled on the straight track, and the welding trolley moves along the curved track. Under the guidance of the laser sensor, the module of the welding gun 9 actuator will make corresponding expansion and contraction changes to compensate for the change of the R angle, so as to weld R fillet welds of different radii. At the same time, the AGV back-protection trolley 5 moves along the criss-crossing navigation strips, and starts and stops at the same time as the welding trolley. The two work closely together to ensure that the weld is well protected during the welding process.

[0068] In summary, the large-scale panel welding production line has effectively improved production efficiency by optimizing workstation design, automated operation, continuous welding process, and fixture flow optimization.

Claims

1. A large-scale panel welding method, characterized in that: The steps include: S1, spot welding of the panel (10), at the assembly station (3), assembling the pre-cut dispersed plates on the platform and fixing them by spot welding to obtain a large panel (10) that meets the welding requirements, detachably clamping four clamps around the panel (10), and ensuring that the outer edges of the four clamps are respectively parallel to the transverse weld and the longitudinal weld, so as to ensure that at the welding station, the chain conveyor adjusts each weld on the panel (10) to the welding position, and after completing the clamp clamping, the panel (10) to be welded is obtained, and the bull's eye wheel array (2) below the splicing station rises, passes through the holes on the splicing platform that are distributed in the same manner as the bull's eye wheel array (2), lifts the panel (10), and separates the panel (10) from the splicing platform, so that the panel (10) to be welded can be conveyed to the next station; S2, the panel (10) to be welded is transported and aligned with the weld seam. The splicing station, welding station and disassembly station (4) are connected in series through a conveying device. The chain conveying device buckles the outer edge of the fixture to transport the panel (10) to the welding station. If the panel (10) tilts in the horizontal direction during the transportation process, the two chain buckles (12) buckled on the edge of the fixture correct the panel (10) through differential transmission. At the welding station, through the mutual cooperation of the chain conveying device, any transverse weld seam and longitudinal weld seam on the panel (10) are aligned with the welding position on the welding station, and at the same time, it is ensured that there is no obstacle under the panel (10) to hinder the movement of the back-up trolley (5); the welded panel (10) is transported to the disassembly station (4) by the chain conveying device on the disassembly station (4), and the fixtures clamped around the panel (10) are disassembled and transported out of the assembly line; S3, welding of the panel (10), the gantry (1) moves forward and backward along the direction of the production line, the hanger on the gantry (1) drives the welding trolley track to move left and right, the welding trolley moves along the welding trolley track, the conveying device of the welding station moves the panel (10), and the transverse weld on the panel (10) is moved to the welding position, or the gantry (1) moves the welding trolley track to the transverse weld position of the panel (10), and the welding trolley and the back-up trolley (5) cooperate with each other to achieve the welding of the transverse weld of the panel (10). After the transverse weld is welded, the welding trolley track is rotated 90 degrees by the rotating device, and the longitudinal weld on the panel (10) is welded by the same method as the transverse weld; S4, the clamp is disassembled, and the chain conveyor conveys the welded panel (10) to the disassembly station (4). After the clamps clamped around the panel (10) are manually disassembled, the clamp is transported to the splicing station by the overhead crane to prepare for the next cycle, and the welded panel (10) is conveyed out of the assembly line; In S2, the welding stations are arranged in an array on the ground with bull's eye wheels at the same height as the splicing stations, a conveying device is installed between the bull's eye wheel arrays (2), and there is a gap in the bull's eye wheel array (2), which serves as a movement space for the back-protection trolley (5).

2. A large-scale panel welding method according to claim 1, characterized in that: In S3, during continuous welding, in order to improve efficiency, four plates are spliced ​​at the assembly station (3) at the same time, and the spliced ​​plates are prepared at the transfer station. The chain buckle (12) on the transfer station pushes the spot-welded plates, pushes the forward push plate, and then pushes the plate being welded, so that the weld seam is aligned with the center of the bull's eye wheel array aisle.

3. A large-scale panel welding method according to claim 1, characterized in that: In said S2, the following steps are also included: S21, weld seam centering, the panel (10) is pushed by a push plate, the front and rear push plates complete the centering of the transverse weld seam, and the left and right push plates are responsible for the centering of the longitudinal weld seam. The weld seams of the panel (10) need to be moved to the center of the bull's eye wheel array (2) so as to cooperate with the back-protection trolley (5) for welding. After the weld seams are centered, they are integrated and a weld seam in place signal is sent to the control unit; S22, the back-protection trolley (5) is reset, the back-protection trolley (5) returns to the starting point, and sends a positioning signal to the control unit.

4. A large-scale panel welding method according to claim 1, characterized in that: In S3, when the panels (10) are welded, the back-protection trolley (5) moves along the weld, and argon gas is continuously passed under the panels (10) to protect the weld.

5. A large-scale panel welding method according to claim 1, characterized in that: The back-protection trolley (5) moves at the same speed as the welding gun (9) at the welding station.

6. A large-scale panel welding method according to claim 1, characterized in that: During the transfer and dragging process of the panel (10), when tilting and deviation occur, so that the weld of the panel (10) cannot be parallel to the aisle of the bull's eye wheel array (2), two chain buckles (12) hooked on the panel (10) apply thrust to the panel (10) at different speeds, and at the same time, two chain buckles (12) on opposite sides are stationary and blocked in the forward direction of the panel (10) to correct the panel (10). In the correction of the panel (10), left-leaning correction and right-leaning correction are included, and the ratio of the differential speed is adjusted according to the size of the tilt angle.

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