Automatic welding equipment and method for manufacturing cold storage balls

Abstract

An automated welding equipment and method for manufacturing cold storage balls belongs to the field of cold storage ball production technology. It solves the problems of low production efficiency, low yield rate, and long working hours in the existing technology. Technical points: A frame table is installed on the frame, and a turntable processing table is installed on the frame table. Eight functional mechanism installation positions are evenly arranged on the frame table. The eight functional mechanism installation positions include seven functional mechanism installation positions and one spare mechanism installation position. The positioning clamps are evenly installed on the turntable processing table; the functional mechanisms include a blanking mechanism, a loading mechanism, a punching mechanism, a liquid injection mechanism, a wire inserting mechanism, a welding mechanism, and a polishing mechanism. The present invention realizes the automated batch production of the entire process including hollow ball loading, processing liquid injection holes, injecting cold storage liquid, sealing and welding the injection holes, polishing the weld points, and blanking cold storage balls, thereby improving production efficiency, saving working hours, and increasing product qualification rate and product quality consistency. It has broad market prospects in the field of cold storage ball production.

Description

Technical Field

[0001] The invention relates to the technical field of cold storage ball production, in particular to automatic assembly and welding equipment and a method for manufacturing cold storage balls. Background Art

[0002] Cold storage technology is a technology that stores cold energy in advance and releases it when needed to achieve cooling and refrigeration effects. It is widely used in cooling and heat dissipation, refrigeration and temperature control, and other fields. For example, it is used as a cold storage radiator for high-power lasers, a cooling system for large power grids or data centers, and a cooling device for the interior of buildings. This reduces dependence on cooling water or chillers, ensuring cooling effects while saving energy and reducing emissions. Among them, volumetric packaged cold storage equipment has become the development direction of cold storage equipment due to its simple structure, high reliability, and good cooling performance. Among them, the cold storage container containing a large number of densely stacked cold storage balls is the core device of the volumetric packaged cold storage equipment. The quality of the cold storage balls directly affects the cold storage performance of the cold storage device.

[0003] A cold storage ball consists of a hollow shell encapsulated with a coolant liquid. Current production of cold storage balls relies heavily on manual labor, with a low degree of automation. The main production process involves securing the hollow shell to a fixture, machining the injection hole, injecting the coolant liquid, sealing and welding the injection hole, polishing the welds, and inspecting the weld quality. This manual production model requires a large number of operators, is labor-intensive and time-consuming, and leads to low production efficiency. Furthermore, it is difficult to operate, resulting in poor welding quality and a high scrap rate. Furthermore, the amount of coolant liquid to be injected relies on manual experience and cannot be quantified, making it prone to inconsistent coolant liquid content. However, a single cold storage unit is composed of a large number of closely packed coolant balls, necessitating a high demand for these balls.

[0004] Therefore, it is urgent to propose an automated welding equipment and method for manufacturing cold storage balls to solve the problems of low production efficiency, low yield and long working hours. Summary of the Invention

[0005] In view of the above facts, in order to solve the problems of low production efficiency, low yield and long working hours, the present invention further designs an automatic welding equipment and method for manufacturing cold storage balls.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] Solution 1: An automated assembly and welding equipment for manufacturing cold storage balls, including: a frame, a frame table, a positioning clamp, a turntable processing table, and a functional mechanism;

[0008] The frame is equipped with a frame table, a turntable processing table is installed on the frame table, eight functional mechanism installation positions are evenly arranged on the frame table, the eight functional mechanism installation positions include seven functional mechanism installation positions and one spare mechanism installation position, and the positioning clamps are evenly installed on the turntable processing table;

[0009] The functional mechanisms include a blanking mechanism, a loading mechanism, a punching mechanism, a liquid injection mechanism, a wire inserting mechanism, a welding mechanism, and a polishing mechanism. The blanking mechanism, the loading mechanism, the punching mechanism, the liquid injection mechanism, the wire inserting mechanism, the welding mechanism, and the polishing mechanism are installed clockwise on seven functional mechanism installation positions.

[0010] Furthermore: the bottom surface of the turntable processing table is connected to the top surface of the reducer, the bottom of the reducer is connected to the servo motor, and a zero point signal sensor is installed on the side of the reducer.

[0011] Further: the control system includes an operation panel, an electric control cabinet and a central control system;

[0012] A control panel is installed on the electric control cabinet, and a central control system is placed in the electric control cabinet. The central control system is used to control the intermittent rotation of the turntable processing table.

[0013] Solution 2: An automated welding method for manufacturing cold storage balls, the specific steps are as follows:

[0014] Step 1: The loading robot picks up the hollow ball from the vibrating plate and places it in the slot of the corresponding positioning clamp of the loading mechanism. The loading step is completed and the turntable rotates 45° clockwise.

[0015] Step 2: The drilling mechanism uses a lifting motor and a high-speed rotating drill bit to drill the hollow ball. After the drilling is completed, the hollow ball with a hole is clamped in the positioning clamp, and the turntable rotates 45° clockwise.

[0016] Step 3: Use the injection mechanism to match the lifting shaft to inject the cold storage liquid into the hollow ball with holes. After the injection is completed, the turntable processing table rotates 45 degrees clockwise;

[0017] Step 4: Insert a small piece of welding wire into the injection hole. After the wire is inserted, rotate the turntable 45° clockwise.

[0018] Step 5: Spot weld the injection hole for inserting the welding wire through the welding mechanism to achieve reliable sealing of the injection hole. After the sealing is completed, the turntable processing table rotates 45° clockwise;

[0019] Step 6: Grind the welding points by rotating the grinding tool at high speed to improve the smoothness of the cold storage ball. After grinding is completed, the turntable rotates 45° clockwise.

[0020] Step 7: The unloading mechanism takes the processed cold storage balls out of the slots of the positioning clamps and places them in the recycling storage basket. After unloading, the turntable rotates 45° clockwise, and the current positioning clamps return to the loading mechanism for the next round of loading and subsequent steps.

[0021] If the positioning clamps on the corresponding workstations of all mechanisms hold balls that have been processed through all or part of the above steps, the automatic production device for cold storage balls will enter a cycle operation, and the functional mechanisms corresponding to the positioning clamps will operate synchronously within the same time cycle;

[0022] Step 8: After the functional mechanism has finished running, the turntable will rotate 45° clockwise. After the rotation is in place, all functional mechanisms will run synchronously again, and the process will be repeated.

[0023] The beneficial effects of the present invention are:

[0024] 1. The present invention realizes the automated batch production of the entire process including hollow ball loading, liquid injection hole processing, cold storage liquid injection, injection hole sealing welding, welding point grinding, cold storage ball unloading, etc., thereby improving production efficiency and saving working hours.

[0025] 2. The present invention is fully automatic in control, effectively improving the product qualification rate and maintaining product quality consistency. The balls after injection and welding have no leakage defects, and the mass after injection is maintained within the range of M±0.01g, where M is the initial weight of the balls. The yield rate is stable at above 90%, meeting production needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is an overall schematic diagram of the present invention;

[0027] Figure 2 It is a plan view of the mechanical part;

[0028] Figure 3 This is a front view of the turntable type processing table;

[0029] Figure 4 It is a top view of the turntable type processing table;

[0030] Figure 5 Flowchart of the operation of the equipment of the present invention.

[0031] In the figure: 1-frame, 2-frame table, 3-positioning clamp, 4-turntable processing table, 5-unloading mechanism, 6-loading mechanism, 7-punching mechanism, 8-liquid injection mechanism, 9-wire insertion mechanism, 10-welding mechanism, 11-grinding mechanism, 12-operation panel, 13-electric control cabinet, 41-reducer, 42-servo motor, 43-zero point signal sensor. DETAILED DESCRIPTION

[0032] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0033] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequential order. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present application described here. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0034] In this application, terms such as "upper," "lower," "inner," "middle," "outer," "front," and "back" indicate positions or locations based on the positions or locations shown in the accompanying drawings. These terms are primarily intended to better describe this application and its embodiments and are not intended to limit the devices, elements, or components indicated to having a specific orientation, or to being constructed or operated in a specific orientation.

[0035] Furthermore, some of the above terms may be used to express other meanings besides indicating a position or location. For example, the term "on" may also be used to indicate a dependency or connection in certain circumstances. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0036] Furthermore, the terms "disposed," "connected," and "fixed" should be interpreted broadly. For example, "connected" can mean a fixed connection, a removable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection, an indirect connection through an intermediary, or an internal communication between two devices, elements, or components. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0037] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments in this application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0038] Preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0039] Example 1: An automated welding equipment for manufacturing cold storage balls, comprising: a frame 1, a frame table 2, a positioning clamp 3, a turntable processing table 4, and a functional mechanism;

[0040] The frame 1 is equipped with a frame table 2, and a turntable processing table 4 is installed on the frame table 2. Eight functional mechanism installation positions are evenly arranged on the frame table 2, and the eight functional mechanism installation positions include seven functional mechanism installation positions and one spare mechanism installation position. The positioning clamps 3 are evenly installed on the turntable processing table 4;

[0041] The functional mechanisms include a blanking mechanism 5, a loading mechanism 6, a punching mechanism 7, a liquid injection mechanism 8, a wire inserting mechanism 9, a welding mechanism 10, and a grinding mechanism 11. The blanking mechanism 5, the loading mechanism 6, the punching mechanism 7, the liquid injection mechanism 8, the wire inserting mechanism 9, the welding mechanism 10, and the grinding mechanism 11 are installed clockwise on seven functional mechanism installation positions.

[0042] More specifically: the loading mechanism 6 is a station for completing the loading of hollow balls, the punching mechanism 7 is a station for processing the injection holes, the injection mechanism 8 is a station for injecting cold storage liquid, the wire inserting mechanism 9 is a station for inserting welding wire (welding nail) into the injection holes, the welding mechanism 10 is a station for sealing spot welding, and the grinding mechanism 11 is a station for grinding the welding points after sealing.

[0043] More specifically: the bottom surface of the turntable processing table 4 is connected to the top surface of the reducer 41, the bottom of the reducer 41 is connected to the servo motor 42, and the side of the reducer 41 is installed with a zero point signal sensor 43;

[0044] The rotatable turntable 4 rotates through the reducer 41 under the drive of the servo motor 42. The zero point signal sensor 43 serves as the starting sensing point to ensure the consistency of the starting point and ensure the high-precision repeatability of the rotation of the turntable 4.

[0045] More specifically: the control system includes a control panel 12, an electric control cabinet 13 and a central control system;

[0046] The electric control cabinet 13 is equipped with a control panel 12, which adopts an integrated design. The central control system is placed in the electric control cabinet 13. The turntable processing table 4 is rotated intermittently through the control panel 12. The control panel 12 can also be used to set production process parameters, display production process information and other soft control monitoring settings.

[0047] More specifically, eight positioning clamps 3 are evenly distributed on the turntable processing table 4 , and each positioning clamp 3 has a slot for clamping and positioning the cold storage ball to be processed.

[0048] More specifically, the unloading mechanism 5 and the loading mechanism 6 are composed of a vacuum generator and a plurality of linear motion cylinders.

[0049] More specifically: the injection mechanism 8 uses a peristaltic pump in conjunction with a Luer connector, and has constant temperature and ultraviolet sterilization functions.

[0050] More specifically: the purpose of the wire insertion mechanism 9 is to provide packaging materials for the next welding step. It has a visual detection function and can identify whether the wire is stably inserted into the hole. At the same time, the wire insertion mechanism is a vacuum generator that cooperates with a moving guide rail to insert the welding wire in the preset welding wire reel into the small hole in sequence. There are 400 welding wire placement positions in the preset welding wire reel, which are arranged in 20x20.

[0051] More specifically, the welding mechanism 10 uses a pulsed laser as a heat source.

[0052] More specifically, the grinding head of the grinding mechanism 11 is a specially made hemispherical shape, and the inner surface of the grinding head fits perfectly with the outer surface of the cold storage ball to be processed.

[0053] Example 2: An automated welding method for manufacturing cold storage balls, comprising the following steps:

[0054] Step 1: The loading robot picks up the hollow ball from the vibrating plate and places it in the slot of the positioning clamp 3 currently corresponding to the loading mechanism 6. The loading step is completed and the turntable processing table 4 rotates 45° clockwise;

[0055] Step 2: The drilling mechanism 7 uses a lifting motor and a high-speed rotating drill bit to drill the hollow ball. After the drilling is completed, the positioning clamp 3 holds the hollow ball with a hole, and the turntable processing table 4 rotates 45 degrees clockwise.

[0056] Step 3: The cooling liquid is injected into the hollow ball with holes through the liquid injection mechanism 8 and the lifting shaft. After the liquid injection is completed, the turntable processing table 4 rotates 45 degrees clockwise;

[0057] Step 4: Insert a small piece of welding wire into the injection hole. After the wire is inserted, rotate the turntable 45° clockwise.

[0058] Step 5: Spot welding is performed on the injection hole for inserting the welding wire (welding nail) by the welding mechanism 10 to achieve reliable sealing of the injection hole. After the sealing welding is completed, the turntable processing table 4 rotates 45° clockwise;

[0059] Step 6: Grind the welding points by rotating the grinding tool at high speed to improve the smoothness of the cold storage ball. After grinding is completed, the turntable processing table 4 rotates 45 degrees clockwise;

[0060] Step 7: The unloading mechanism 5 takes the processed cold storage ball out of the card slot of the positioning clamp 3 and places it in the recovery storage basket. After unloading, the turntable processing table 4 rotates 45 degrees clockwise, and the current positioning clamp 3 returns to the loading mechanism 6 to carry out the next round of loading and subsequent steps;

[0061] If the positioning clamps 3 on the corresponding workstations of all the mechanisms hold the balls that have been processed through all or part of the above steps, the automatic production equipment for cold storage balls will enter a cycle operation, and the functional mechanisms corresponding to the positioning clamps 3 will operate synchronously within the same time cycle;

[0062] Step 8: After the functional mechanism has finished running, the turntable processing table 4 rotates 45 degrees clockwise. After the rotation is in place, all functional mechanisms will run synchronously again, and the process will be repeated.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, the technical solutions described in the aforementioned embodiments can still be modified, or some or all of the technical features therein can be replaced by equivalents. As long as there is no structural conflict, the various features in the specific implementation methods disclosed in this application can be combined with each other in any way, and the essence of the corresponding technical solutions will not deviate from the scope of the technical solutions of the present invention.

[0064] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method 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 can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. An automated welding method for manufacturing cold storage balls, which is implemented by automated welding equipment for manufacturing cold storage balls, the automated welding equipment comprising: A machine frame (1), a machine frame table (2), a positioning clamp (3), a turntable processing table (4), and a functional mechanism; The frame (1) is mounted with a frame table (2), a turntable processing table (4) is mounted on the frame table (2), eight functional mechanism mounting positions are evenly arranged on the frame table (2), the eight functional mechanism mounting positions include seven functional mechanism mounting positions and one standby mechanism mounting position, and positioning clamps (3) are evenly mounted on the turntable processing table (4); The functional mechanism comprises a blanking mechanism (5), a feeding mechanism (6), a punching mechanism (7), a liquid injection mechanism (8), a wire inserting mechanism (9), a welding mechanism (10), and a grinding mechanism (11), wherein the blanking mechanism (5), the feeding mechanism (6), the punching mechanism (7), the liquid injection mechanism (8), the wire inserting mechanism (9), the welding mechanism (10), and the grinding mechanism (11) are mounted on seven functional mechanism mounting positions in a clockwise direction; It is characterized in that the specific steps are: Step 1: The loading robot picks up the hollow ball from the vibrating plate and places it in the slot of the positioning clamp (3) currently corresponding to the loading mechanism (6). The loading step is completed and the turntable processing table (4) rotates 45° clockwise; Step 2: The drilling mechanism (7) uses a lifting motor and a high-speed rotating drill bit to drill the hollow ball. After the drilling is completed, the positioning clamp (3) holds the hollow ball with a hole, and the turntable processing table (4) rotates 45 degrees clockwise. Step 3: The cooling liquid is injected into the hollow ball with holes through the liquid injection mechanism (8) and the matching lifting shaft. After the liquid injection is completed, the turntable processing table (4) rotates 45 degrees clockwise; Step 4: Insert a small piece of welding wire into the injection hole. After the wire insertion is completed, the turntable (4) rotates 45° clockwise. Step 5: Spot welding the injection hole for inserting the welding wire is performed by the welding mechanism (10) to achieve reliable sealing of the injection hole. After the sealing welding is completed, the turntable processing table (4) is rotated 45° clockwise; Step 6: Grind the welding point by rotating the grinding tool at high speed to improve the smoothness of the cold storage ball. After the grinding is completed, the turntable (4) rotates 45° clockwise; Step 7: The unloading mechanism (5) takes the processed cold storage ball out of the slot of the positioning clamp (3) and places it in the recycling storage basket. After unloading, the turntable processing table (4) rotates 45° clockwise, and the current positioning clamp (3) returns to the loading mechanism (6) to carry out the next round of loading and subsequent steps; If the positioning clamps (3) on the corresponding workstations of all the mechanisms all hold the balls that have been processed through all or part of the above steps, the automatic production equipment for cold storage balls will enter a cycle operation, and the functional mechanisms corresponding to the positioning clamps (3) will operate synchronously within the same time cycle; Step 8: After the functional mechanism has finished operating, the turntable (4) rotates 45° clockwise. After the rotation is in place, all functional mechanisms will operate synchronously again, and the process will repeat in this way.

2. The automated welding method for manufacturing cold storage balls according to claim 1, characterized in that: The bottom surface of the turntable processing table (4) is connected to the top surface of the reducer (41), the bottom of the reducer (41) is connected to the servo motor (42), and a zero point signal sensor (43) is installed on the side of the reducer (41).

3. The automated welding method for manufacturing cold storage balls according to claim 1, characterized in that: The control system includes a control panel (12), an electric control cabinet (13) and a central control system; The electric control cabinet (13) is provided with a control panel (12), and a central control system is placed in the electric control cabinet (13). The central control system is used to control the intermittent rotation of the turntable processing table (4).

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