Assembly line type building prefabricated slab unmanned welding system and method

Abstract

The invention relates to the technical field of building prefabricated slab welding in the building field, in particular to an assembly line type building prefabricated slab unmanned welding system and method, and the system comprises a feeding unit, a conveying unit, an automatic clamping unit, an automatic locating unit, an automatic welding unit, an automatic stacking unit and a whole line control unit. The automatic clamping unit comprises a blocking mechanism, a forward pushing in-place mechanism, a jacking supporting mechanism and a station pressing mechanism. The automatic locating unit is used for photographing the relative positions of the steel bar frame and the iron sheet holes in the cement fiber base plate through the 3D visual system, calculating the coordinates of the avoiding holes and transmitting the coordinates of the avoiding holes to the automatic welding unit; the automatic welding unit is used for performing spot welding on the steel bar frame and the cement fiber base plate iron sheet assembly according to the avoiding hole coordinates; and the automatic stacking unit is used for stacking the assembled and welded finished products of the cement fiber base plates and the steel bar frames. The qualified rate of the building prefabricated slabs can be increased, the production efficiency of the building prefabricated slabs can be improved, and the labor cost can be saved.

Description

Technical Field

[0001] The invention relates to the technical field of welding of prefabricated building panels in the construction field, and in particular to an assembly line type unmanned welding system and method for prefabricated building panels. Background Art

[0002] The rapid development of modern construction technology has put forward higher requirements on the strength, structural safety and construction efficiency of housing structures. Prefabricated panels are the foundation plates of cast-in-place slabs between floors in the frame-type building structure of the construction industry. In order to improve the construction efficiency of the construction site, prefabricated panels appear as a modular structure to replace the manual on-site floor lap steel frames to meet the subsequent cast-in-place floor production. Prefabricated panel manufacturers produce prefabricated panels of specified specifications and sizes according to orders, and then transport them to the construction site, assemble them between floors, and then cast cement to make floor slabs.

[0003] like Figure 1 As shown, the building prefabricated panel includes a steel frame 1 and a cement fiber substrate 2, and the cement fiber substrate 2 includes a foundation iron sheet 3. At present, the realization of the steel frame and the cement fiber substrate assembly welding includes spot welding by manually holding a welding gun. The manual welding process of the steel frame and the cement fiber substrate assembly welding includes: S1, manually lifting the cement fiber substrate to the ground welding area; S2, manually moving the steel frame to the cement fiber board foundation iron sheet area; S3, due to the deformation of the steel frame, the steel frame and the foundation iron sheet have only partial contact points, and the steel frame is manually spot welded to fix these contact points; S4, manually using the steel bar to pry and press the steel frame itself to fit the empty points that are not in contact with the foundation iron sheet, one hand prying and one hand spot welding. If the deformation is too large, other personnel are required to assist; S5, according to S2-S4, a total of 4 cycles are performed to complete the spot welding of 4 steel frames. There are some shortcomings in these current technologies: the product qualification rate is very low, because the steel frame is manually pried and pressed to make it fit and weld, resulting in a relatively low qualification rate, and manual welding is required later. The production efficiency is low, 5-6 pieces of 3000*1200 prefabricated panels are welded per person in 10 hours. The labor intensity is high and the labor intensity is high. The prefabricated panel business belongs to the centralized order business. The production of thousands or tens of thousands of square meters of prefabricated panels per unit time requires a large amount of labor to be concentrated in a short time. Summary of the invention

[0004] In order to solve the technical problems existing in the prior art, the present invention provides an assembly line type unmanned welding system and method for prefabricated building panels. By setting an automatic clamping unit, an automatic positioning unit and an automatic welding unit, the qualified rate of prefabricated building panels can be improved, the production efficiency of prefabricated building panels can be improved and labor costs can be saved.

[0005] The purpose of the present invention can be achieved by adopting the following technical solutions:

[0006] An assembly line type building prefabricated panel unmanned welding system, comprising: a loading unit, a conveying unit, an automatic clamping unit, an automatic positioning unit, an automatic welding unit, an automatic stacking unit and a whole line control unit;

[0007] The conveying unit includes a main conveying line and a material stack conveying line. The main conveying line is used to convey the cement fiber substrate, the steel frame and its components to each workstation, and convey the finished welded cement fiber substrate and the steel frame to the end of the main conveying line; the material stack conveying line is used to convey the stacked welded finished products;

[0008] The loading unit is used to transport the cement fiber substrate and the steel bar frame to the main conveyor line respectively, and match the steel bar frame to the cement fiber substrate to obtain a cement fiber substrate and steel bar frame assembly;

[0009] The automatic clamping unit includes a blocking mechanism, a forward push-to-position mechanism, a jacking support mechanism, and a workstation pressing mechanism. The assembly of the cement fiber substrate and the steel frame is positioned by the blocking mechanism and the forward push-to-position mechanism. The bottom of the cement fiber substrate is supported by the jacking support mechanism. The steel frame is pressed onto the cement fiber substrate by the workstation pressing mechanism, so that the steel frame and the cement fiber substrate are in contact with each other.

[0010] The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron holes on the cement fiber substrate through a 3D vision system, calculate the avoidance hole coordinates and transmit the avoidance hole coordinates to the automatic welding unit;

[0011] The automatic welding unit spot-welds the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system to obtain a finished product of the cement fiber substrate and the steel frame;

[0012] The automatic stacking unit is used to stack the finished products of the cement fiber base plate and the steel bar frame;

[0013] The whole line control unit is respectively connected to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit, and is used to issue control action instructions to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit and monitor the operating status in real time.

[0014] Specifically, the main conveyor line is provided with a plurality of workstations, including: workstation 1 is the cement fiber board loading position, workstation 2 is the cement fiber base plate and steel frame matching position, workstation 3 is the cement fiber base plate and steel frame first welding position, workstation 4 is the cement fiber base plate and steel frame second welding position, workstations 5 and 6 are the assembly welding finished product waiting for sampling position, and workstation 7 is the finished product stacking and taking-out position.

[0015] Specifically, the loading unit includes: a cement fiber substrate destacking robot and a hand gripper, a steel frame handling robot and a hand gripper, and a steel frame conveyor line. The cement fiber substrate destacking robot grabs the cement fiber substrate from the incoming material pallet and places it on the workstation 1 on the main conveyor line by means of a hand gripper. The main conveyor line transports the cement fiber substrate from the workstation 1 to the workstation 2. The steel frame handling robot transports the steel frame from the steel frame conveyor line to the cement fiber substrate.

[0016] Specifically, the blocking mechanism includes a motor and a blocking plate, the motor and the blocking plate are in transmission connection, and the motor and the blocking plate are arranged on the main conveying line;

[0017] The forward push mechanism comprises a motor and a forward push plate, the motor and the forward push plate are in driving connection, and the motor drives the forward push plate to position the steel bar frame assembly onto the cement fiber substrate;

[0018] The lifting support mechanism includes a hydraulic lifting device, which is arranged at workstations 3 and 4, and is installed below the bottom of the cement fiber substrate to support the bottom of the cement fiber substrate upwards;

[0019] The workstation clamping mechanism includes multiple sets of clamping cylinders and a gantry fixing frame, multiple sets of clamping cylinders are fixedly arranged on the gantry fixing frame, multiple sets of clamping cylinders are located above the cement fiber base plate and the steel bar frame assembly, the clamping cylinder includes a cylinder and a cylinder push rod, and the cylinder is connected to the cylinder push rod; when the clamping cylinder is working, the cylinder push rod of the clamping cylinder presses down to contact the steel bar frame of the cement fiber base plate and the steel bar frame assembly, so that the steel bar frame is completely fitted with the cement fiber base plate surface.

[0020] Specifically, the 3D vision system includes multiple 3D industrial cameras and an industrial computer. The multiple 3D industrial cameras are respectively connected to the industrial computer and are respectively installed at different positions on the gantry fixed frame. The 3D industrial cameras are located above the steel frame and cement fiber substrate assembly.

[0021] Specifically, the automatic welding unit includes multiple welding robots, a welding power supply, and a welding control system. The welding robots are electrically connected to the welding power supply and the welding control system, respectively. The multiple welding robots are respectively arranged on both sides of the workstations 3 and 4 of the main conveyor line.

[0022] Specifically, the automatic palletizing unit includes a palletizing robot, a hand gripper, and a transfer table. The palletizing robot grabs qualified finished welded products from station 7 and stacks them on a qualified pallet; puts qualified finished welded products that need to be flipped over for palletizing on the transfer table, grabs them in reverse and stacks them on a qualified pallet; and stacks unqualified products on an unqualified pallet.

[0023] An unmanned welding method for assembly line type prefabricated building panels, comprising:

[0024] S1, transporting the cement fiber substrate from the predetermined stack to the main conveyor line station 1 by the cement fiber substrate destacking robot, centering and positioning the cement fiber substrate at station 1, and continuing to transport the cement fiber substrate to the main conveyor line station 2 for blocking and positioning by the blocking mechanism;

[0025] S2, transporting the steel frame from the steel frame conveyor line to the main conveyor line station 2 by a transport robot, and positioning the steel frame and the cement fiber substrate to form a cement fiber substrate and steel frame assembly by a forward push mechanism;

[0026] S3, the mud fiber substrate and the steel frame assembly are transported to the main conveyor line station 3, the bottom of the mud fiber substrate is supported by water through the jacking support mechanism, and the steel frame is pressed on the cement fiber substrate through the station pressing mechanism, so that the steel frame and the cement fiber substrate surface are in contact;

[0027] S4, taking photos of the relative positions of the steel frame and the iron holes on the cement fiber substrate through the 3D vision system; calculating the relative positions of the steel frame and the iron holes on the cement fiber substrate, and the 3D vision system transmits the avoidance hole coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, and obtains the semi-finished product of the cement fiber substrate and the steel frame;

[0028] S5, the semi-finished product of the semi-cement fiber substrate and the steel frame is transported to the main conveyor line station 4, and the steel frame and the cement fiber substrate iron sheet component are spot welded for the second time by the automatic welding unit according to the avoidance hole coordinates transmitted by the 3D vision system to obtain the finished product of the cement fiber substrate and the steel frame;

[0029] S6. The finished products of the cement fiber substrate and the steel frame are transported to the main conveyor line stations 5 and 6, and the finished products of the welding are sampled to check whether they are qualified.

[0030] The S7 palletizing robot grabs qualified finished welded products from station 7 and palletizes them on qualified pallets; it places qualified finished welded products that need to be flipped over for palletizing on the transfer table, grabs them in reverse and palletizes them on qualified pallets; it palletizes unqualified products on unqualified pallets.

[0031] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0032] The present invention provides an assembly line type unmanned welding system and method for prefabricated panels of buildings. The assembly of cement fiber base plate and steel bar frame is positioned by a blocking mechanism and a forward pushing mechanism. The bottom of the cement fiber base plate is supported by water through a jacking support mechanism. The steel bar frame is pressed onto the cement fiber base plate by a workstation pressing mechanism to make the steel bar frame fit with the surface of the cement fiber base plate. The problem of manually using a steel chisel to pry and press the untouched points of the steel bar frame to fit the base iron sheet, and to pry and press with one hand and spot weld with the other hand, and requiring assistance from other personnel if deformation is too large, can be overcome.

[0033] The relative positions of the steel frame and the iron holes on the cement fiber substrate are photographed by the 3D vision system; the relative positions of the steel frame and the iron holes on the cement fiber substrate are calculated, and the 3D vision system transmits the avoidance hole coordinates to the automatic welding unit; the automatic welding unit spot welds the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, and obtains a finished product of the cement fiber substrate and the steel frame, which can improve the qualified rate of the prefabricated panels of the building, improve the production efficiency of the prefabricated panels of the building and save labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] 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 briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0035] Figure 1 is a schematic diagram of the structure of a prefabricated building panel in an embodiment of the present invention;

[0036] Figure 2 It is a schematic diagram of the overall structure of an assembly line type unmanned welding system for prefabricated panels of buildings in an embodiment of the present invention;

[0037] Figure 3 It is a site layout diagram of an assembly line type unmanned welding system for prefabricated panels of buildings in an embodiment of the present invention;

[0038] Figure 4 Schematic diagram of the main conveyor line station in an embodiment of the present invention;

[0039] Figure 5 is a schematic diagram of the cement fiber substrate destacking robot and hand gripping application layout in an embodiment of the present invention;

[0040] Figure 6 is a schematic diagram of the layout of the steel frame handling robot and hand-grasping application in an embodiment of the present invention;

[0041] Figure 7is a schematic diagram of a blocking mechanism in an embodiment of the present invention;

[0042] Figure 8 is a schematic diagram of a jacking support mechanism in an embodiment of the present invention;

[0043] Fig. 9 is a schematic diagram of a station clamping mechanism in an embodiment of the present invention;

[0044] Fig.10 Schematic diagram of the relative positions of the steel frame and the iron holes on the cement fiber substrate in an embodiment of the present invention;

[0045] The numbers in the figure are: 1-steel frame, 2-cement fiber substrate, 3-basic iron sheet, 4-incoming material pallet, 5-cement fiber substrate destacking robot, 51-hand grip of cement fiber substrate destacking robot, 6-steel frame conveyor line, 7-steel frame handling robot, 71-hand grip of steel frame handling robot, 8-welding control system, 9-welding robot, 10-assembly welding finished product waiting for sampling position, 11-stacking robot, 12-material stacking conveyor line, 13-station 1, 14-station 2, 15-station 3, 16-station 4, 17-station 5, 18-station 6, 19-station 7, 20-motor, 21-blocking plate, 22-hydraulic cylinder, 23-supporting structure, 24-pressing cylinder, 25-gantry fixing frame, 26-iron sheet hole, 27-weldable position. DETAILED DESCRIPTION

[0046] The technical solution of the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is obvious that the described embodiments are part of the embodiments of the present invention, not all of the embodiments, and the implementation of the present invention is not limited to this. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0047] Embodiment 1:

[0048] like Figure 2 As shown, an unmanned welding system for prefabricated panels of a building in an assembly line includes: a conveying unit, a feeding unit, an automatic clamping unit, an automatic positioning unit, an automatic welding unit, an automatic stacking unit and a whole line control unit, and the conveying unit, the feeding unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit are all electrically connected to the whole line control unit. Among them:

[0049] The conveying unit includes a main conveying line and a material stacking conveying line. The main conveying line is used to convey the cement fiber substrate, the steel frame and its components to each workstation to complete the predetermined function, and to convey the finished product of the cement fiber substrate and the steel frame to the end of the main conveying line for stacking. Figure 3As shown, a site layout diagram of an assembly line type building prefabricated panel unmanned welding system, in a scene of an assembly line type building prefabricated panel unmanned welding system, the site settings include the incoming material tray 4 of the loading unit, the cement fiber substrate destacking robot 5, the cement fiber substrate destacking robot's hand grip 51, the steel frame conveyor line 6, the steel frame handling robot 7 and the steel frame handling robot's hand grip 71, the welding control system 8 of the automatic welding unit, the welding robot 9, the assembly welding finished product waiting for sampling 10, the automatic stacking unit's stacking robot 11, the material stacking conveyor line 12 and other settings. Figure 4 As shown in the figure, it is a schematic diagram of the main conveyor line. The main conveyor line includes 7 stations. Station 1 is the cement fiber board loading station, which is used for loading cement fiber boards. Station 2 is the cement fiber substrate and steel frame matching station, which is used for loading the steel frame, matching and positioning the steel frame with the cement fiber substrate, and obtaining the cement fiber substrate and steel frame assembly. Station 3 is the cement fiber substrate and steel frame primary welding station, which is used to perform the first preliminary welding of the cement fiber substrate and steel frame assembly through the automatic welding unit to obtain the preliminary welded parts of the cement fiber substrate and steel frame. Station 4 is the cement fiber substrate and steel frame secondary welding station, which is used to clamp the unit cement fiber substrate and steel frame through automatic clamping, perform the second comprehensive welding of the cement fiber substrate and steel frame, and obtain the finished product of the cement fiber substrate and steel frame. Stations 5 and 6 are the sampling inspection positions for the finished product of the welding, which are used to sample the finished product of the welding of the cement fiber substrate and the steel frame to obtain the qualified and unqualified products of the welding. Station 7 is the finished product stacking and material taking position, and the stacking robot stacks the qualified products.

[0050] The material stacking conveyor line is used to convey the finished welded products after palletizing, including an empty pallet loading position, an empty pallet temporary storage position, a palletizing position, a full pallet temporary storage position, and a full pallet unloading position, so as to realize the empty pallet loading, empty pallet temporary storage, palletizing of the welded products of the cement fiber base plate and the steel bar frame, and storage of the full pallet.

[0051] The loading unit is used to transport the cement fiber substrate and the steel bar frame to the main conveyor line respectively, and match the steel bar frame to the cement fiber substrate. Specifically, the loading unit includes: 1 set of cement fiber substrate destacking robot 5 and hand gripper 51, 1 set of steel bar frame conveyor line 6, 1 set of steel bar frame handling robot 7 and hand gripper 71. In this embodiment, the cement fiber substrate is placed on the incoming material pallet 4, and the cement fiber substrate destacking robot 5 grabs the cement fiber substrate from the incoming material pallet and places it on the main conveyor line through the hand gripper 51. The steel bar frame handling machine 7 transports 4 steel bars from the steel bar frame conveyor line to the cement fiber substrate in two times. Figure 5 As shown in FIG. 1 , a schematic diagram of the layout of the cement fiber substrate destacking robot and the hand gripping application in an embodiment of the present invention. Figure 6 As shown, a schematic diagram of the layout of the steel frame handling robot and hand-grasping application in an embodiment of the present invention.

[0052] In this embodiment, the cement fiber substrate destacking robot and hand gripper realize the destacking of the cement fiber substrate from the pallet to the workstation 1 of the conveying unit, the main conveyor line conveys the cement fiber substrate from the workstation 1 to the workstation 2, and the steel bar frame handling robot and hand gripper realize the transportation of 4 steel bars from the steel bar frame conveyor line to the workstation 2 of the conveying unit in two times to match the cement fiber substrate.

[0053] The automatic clamping unit includes a blocking mechanism, a forward push-in-place mechanism, a jacking support mechanism, and a workstation clamping mechanism. The blocking mechanism and the forward push-in-place mechanism are used to position the assembly of the cement fiber base plate and the steel bar frame. The jacking support mechanism and the workstation clamping mechanism press the steel bar frame onto the cement fiber base plate to make the steel bar frame fit the cement fiber base plate surface.

[0054] Specifically, the blocking mechanism is used to block the cement fiber substrate and the steel frame assembly in a discrete state at the conveyor line station, so that the cement fiber substrate and the steel frame assembly stop after reaching a predetermined position. Figure 7 As shown, a schematic diagram of the blocking mechanism, the blocking mechanism includes a blocking plate 20 and a motor 21, the motor and the blocking plate are transmission connected, the motor and the blocking plate are arranged on the main conveying line, when the blocking plate is perpendicular to the main conveying line by controlling the motor, the blocking mechanism is in a blocking state; when the blocking plate is parallel to the main conveying line by controlling the motor, the blocking mechanism is in a passing state.

[0055] The forward push mechanism comprises a motor and a forward push plate, which are connected by transmission. The motor drives the forward push plate to position the steel bar frame assembly on the cement fiber substrate, which can meet the positioning requirements of cement fiber substrates within a certain range of sizes.

[0056] The lifting support mechanism includes a hydraulic lifting device, which is arranged at workstation 3 and workstation 4. The hydraulic lifting device is installed below the bottom of the cement fiber substrate and is used to support the bottom of the cement fiber substrate upward. The hydraulic lifting device includes a hydraulic cylinder 22, and a telescopic rod is arranged inside the hydraulic cylinder. The end of the telescopic rod away from the hydraulic cylinder is fixedly connected to a supporting structure 23. The hydraulic cylinder is fixed on the base bracket, and the telescopic rod is connected to the supporting structure to support the bottom of the cement fiber substrate upward so that the surface of the cement fiber substrate is not deformed when the workstation clamping mechanism clamps and positions the steel frame. Figure 8 As shown, the schematic diagram of the jacking support mechanism.

[0057] like Fig. 9As shown, the schematic diagram of the station clamping mechanism, the station clamping mechanism includes multiple sets of clamping cylinders 24 and gantry fixing frames 25, multiple sets of clamping cylinders are fixedly arranged on the gantry fixing frames, multiple sets of clamping cylinders are located above the cement fiber substrate and steel bar frame assembly, the clamping cylinders include cylinders and cylinder push rods, and the cylinders are connected to the cylinder push rods. When the clamping cylinders are working, the cylinder push rods of the clamping cylinders press down to contact the steel bars of the cement fiber substrate and steel bar frame assembly, so that the steel bars and the cement fiber substrate surface are completely fitted.

[0058] In this embodiment, at workstations 3 and 4, the hydraulic jacking device raises the cement fiber base plate and the steel bar frame. When the cement fiber base plate and the steel bar frame are pressed and positioned, the E-plate surface of the cement fiber base plate is ensured not to be deformed. The cylinder push rod of the pressing cylinder is pressed down to contact the steel bar frame of the cement fiber base plate and the steel bar frame assembly, so that the steel bar frame is completely fitted with the base plate surface.

[0059] The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron holes on the cement fiber substrate through the 3D vision system; the relative positions of the steel frame and the iron holes on the cement fiber substrate are calculated, and the 3D vision system transmits the hole coordinates to the automatic welding unit.

[0060] Specifically, the 3D vision system includes multiple 3D industrial cameras and industrial computers. The multiple 3D industrial cameras are connected to the industrial computers respectively. The multiple 3D industrial cameras are installed at different positions on the gantry fixed frame. The 3D industrial cameras are located above the steel frame and cement fiber substrate assembly. The relative positions of the steel frame and the iron holes on the cement fiber substrate are photographed by the 3D industrial cameras and transmitted to the industrial computers. Fig.10 As shown, a schematic diagram of the relative positions of the steel bar frame and the iron sheet holes on the cement fiber substrate. Since the iron sheet holes on the cement fiber substrate are mesh-shaped, the iron sheet is embedded in the cement fiber substrate. When the steel bar is to be spot welded on the iron sheet, which iron sheet hole is to be avoided, such as cement material, the coordinates of the iron sheet hole 26 need to be calculated, that is, the coordinates of the avoided hole are obtained. The industrial computer calculates the avoided hole coordinates based on the photos transmitted by the 3D industrial camera, and the industrial computer transmits the avoided hole coordinates to the automatic welding unit, guiding the welding robot of the automatic welding unit to perform spot welding, spot welding the steel bar frame and the weldable point 27 of the iron sheet on the cement fiber substrate to fix the steel bar frame.

[0061] The automatic welding unit includes multiple welding robots, welding power supplies, and welding control systems. The welding robots are electrically connected to the welding power supplies and welding control systems, respectively. The multiple welding robots are arranged on both sides of stations 3 and 4 of the main conveyor line. Specifically, the welding robot includes a robot body, a wire feeder, and a welding gun. The eight welding robots are respectively located on both sides of stations 3 and 4 of the conveyor line. Under the guidance of the 3D vision system, the steel frame and the cement fiber substrate iron sheet are spot welded to form the finished welded products of the cement fiber substrate and the steel frame. The finished welded products are continuously transported to stations 5 and 6 of the main conveyor line. Stations 5 and 6 are the sampling positions for the finished welded products. The finished welded products are manually sampled to see if they are qualified finished welded products.

[0062] The automatic palletizing unit includes a palletizing robot, a hand gripper, and a transfer table. The finished welded products of the cement fiber substrate and the steel frame are transported to the main conveyor line station 7 for positioning. The palletizing robot grabs the qualified welded products from station 7 and palletizes them on a qualified pallet; the qualified welded products that need to be flipped for palletizing are placed on the transfer table, and then reversely grabbed and palletized on a qualified pallet; the unqualified products are palletized on an unqualified pallet, completing the entire production process.

[0063] The whole line control unit is connected to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit, respectively, and is used to issue control action instructions to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit, and to monitor the operation status in real time. Specifically, the whole line control unit includes a master control cabinet, a touch screen, a PLC control system, and a display screen, which are used to issue action instructions to each execution unit, and to monitor the operation status of each execution unit, the production order status, and the alarm information in real time.

[0064] The present embodiment provides an unmanned welding system for assembly line type prefabricated panels for buildings. According to the production calculation of 3000*1200 prefabricated panels, the unmanned welding production line for prefabricated panels of the technical solution of the present invention is 600 pieces / 10 hours, and one person is required to replenish the steel frame; 50 pieces / 10 hours / 10 people; it is more than 10 times the manual production capacity. The qualified rate of prefabricated panels produced by the unmanned welding production line for prefabricated panels of the technical solution of the present invention is more than 99%; the qualified rate of prefabricated panels welded manually is more than 80%. The unmanned welding production line for prefabricated panels of the technical solution of the present invention is not restricted by personnel and can provide guarantee for production orders. On the whole, the present invention provides an unmanned welding system for assembly line type prefabricated panels for buildings, which can improve the production efficiency of prefabricated panels for buildings, save labor costs, and improve the qualified rate of prefabricated panels for buildings.

[0065] Based on the above-mentioned unmanned welding system for assembly line type building prefabricated panels, the present invention also provides an unmanned welding method for assembly line type building prefabricated panels, comprising the steps of:

[0066] S1, transporting the cement fiber substrate from the predetermined stack to the main conveyor line station 1 by the cement fiber substrate destacking robot, centering and positioning the cement fiber substrate at station 1, and continuing to transport the cement fiber substrate to the main conveyor line station 2 for blocking and positioning by the blocking mechanism;

[0067] S2, transporting the steel frame from the steel frame conveyor line to the main conveyor line station 2 by a transport robot, and positioning the steel frame and the cement fiber substrate to form a cement fiber substrate and steel frame assembly by a forward push mechanism;

[0068] S3, the cement fiber substrate and the steel frame assembly are transported to the main conveyor line station 3, the bottom of the cement fiber substrate is supported by the jacking support mechanism, and the steel frame is pressed on the cement fiber substrate by the station pressing mechanism, so that the steel frame and the cement fiber substrate surface are in contact;

[0069] Specifically, station 3 is the first welding position of the cement fiber substrate and the steel frame. A set of hydraulic jacking devices is set at the bottom of the cement fiber substrate to rise, and 8 sets of clamping cylinders are set above the steel frame to press down to achieve the compression and fixation of the steel frame and cement fiber substrate assembly.

[0070] S4. Take photos of the relative positions of the steel frame and the iron holes on the cement fiber substrate through the 3D vision system; calculate the relative positions of the steel frame and the iron holes on the cement fiber substrate, and the 3D vision system transmits the avoidance hole coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, and obtains the welded semi-finished product of the cement fiber substrate and the steel frame.

[0071] Specifically, two industrial cameras suspended above the main conveyor line station 3 take pictures of the steel frame and the iron holes of the cement fiber board foundation, and send the positioning coordinates to four welding robots through the system algorithm; the four welding robots on the main conveyor line station 3 spot weld the cement fiber base plate and the steel frame assembly under visual guidance, complete the spot welding work of the component part, and produce semi-finished components;

[0072] S5, the semi-finished product of the welding of the semi-cement fiber base plate and the steel frame is transported to the main conveyor line station 4, and the steel frame and the cement fiber base plate iron sheet component are spot welded for the second time by the automatic welding unit according to the avoidance hole coordinates transmitted by the 3D vision system to obtain the finished product of the welding of the cement fiber base plate and the steel frame.

[0073] Specifically, station 4 is the second welding station for the cement fiber substrate and the steel frame. A hydraulic jacking device is set at the bottom of the cement fiber substrate to rise, and 8 sets of clamping cylinders are set above the steel frame to press down to clamp and fix the steel frame and cement fiber substrate assembly. The 4 welding robots at station 4 of the main conveyor line spot weld the semi-finished assembly under visual guidance, complete the assembly spot welding work, and produce the finished product of the cement fiber substrate and the steel frame;

[0074] S6. The finished welded products of cement fiber substrate and steel bar frame are transported to the main conveyor line station 5 and station 6. Station 5 and station 6 are the positions for sampling inspection of the finished welded products. The finished welded products are sampled to check whether they are qualified.

[0075] S7. The palletizing robot grabs the qualified finished welded products from station 7 and stacks them on the qualified pallet. Station 7 is the material picking position for finished product palletizing. The qualified finished welded products that need to be flipped over for palletizing are placed on the transfer table, and then grabbed in reverse and stacked on the qualified pallet. The unqualified products are stacked on the unqualified pallet to complete the entire production process.

[0076] In summary, the present invention provides an assembly line type unmanned welding system and method for prefabricated panels for buildings, which positions the assembly of the cement fiber base plate and the steel bar frame through a blocking mechanism and a forward push-to-position mechanism, supports the bottom of the cement fiber base plate with water through a jacking support mechanism, and presses the steel bar frame onto the cement fiber base plate through a workstation clamping mechanism, so that the steel bar frame and the cement fiber base plate surface are fitted together; the problem of manually using a steel bar to pry and press the untouched points of the steel bar frame to fit the foundation iron sheet with the steel bar frame itself, prying and pressing with one hand and spot welding with the other hand, and requiring assistance from other personnel if the deformation is too large, can be overcome. The relative positions of the steel frame and the iron holes on the cement fiber substrate are photographed by the 3D vision system; the relative positions of the steel frame and the iron holes on the cement fiber substrate are calculated, and the 3D vision system transmits the avoidance hole coordinates to the automatic welding unit; the automatic welding unit spot welds the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, and obtains a finished product of the cement fiber substrate and the steel frame, which can improve the qualified rate of the prefabricated panels of the building, improve the production efficiency of the prefabricated panels of the building and save labor costs.

[0077] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be equivalent replacement methods and are included in the protection scope of the present invention.

Claims

1. An unmanned welding system for assembly line prefabricated panels of buildings, characterized in that: It includes loading unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, automatic stacking unit and whole line control unit; The conveying unit includes a main conveying line and a material stack conveying line. The main conveying line is used to convey the cement fiber substrate, the steel bar frame and its components to each workstation, and convey the finished product of the cement fiber substrate and the steel bar frame to the end of the main conveying line; the material stack conveying line is used to convey the finished product of the cement fiber substrate and the steel bar frame after palletizing. The loading unit is used to transport the cement fiber substrate and the steel bar frame to the main conveyor line respectively, and match the steel bar frame to the cement fiber substrate to obtain a cement fiber substrate and steel bar frame assembly; The automatic clamping unit includes a blocking mechanism, a forward push-to-position mechanism, a jacking support mechanism, and a workstation pressing mechanism. The assembly of the cement fiber substrate and the steel frame is positioned by the blocking mechanism and the forward push-to-position mechanism. The bottom of the cement fiber substrate is supported by the jacking support mechanism. The steel frame is pressed onto the cement fiber substrate by the workstation pressing mechanism, so that the steel frame and the cement fiber substrate are in contact with each other. The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron holes on the cement fiber substrate through the 3D vision system; calculate the relative positions of the steel frame and the iron holes on the cement fiber substrate, and the 3D vision system transmits the coordinates of the holes to the automatic welding unit; The automatic welding unit spot-welds the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system to obtain a finished product of the cement fiber substrate and the steel frame; The automatic stacking unit is used to stack the finished products of the cement fiber base plate and the steel bar frame; The whole line control unit is respectively connected to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit, and is used to issue control action instructions to the feeding unit, the conveying unit, the automatic clamping unit, the automatic positioning unit, the automatic welding unit, and the automatic stacking unit and monitor the operating status in real time.

2. The unmanned welding system for prefabricated panels of a building according to claim 1 is characterized in that: The main conveyor line is provided with a plurality of workstations, including: workstation 1 is the loading position for cement fiber boards, workstation 2 is the matching position for cement fiber substrates and steel bars, workstation 3 is the first welding position for cement fiber substrates and steel bars, workstation 4 is the second welding position for cement fiber substrates and steel bars, workstations 5 and 6 are the positions for sampling of finished welded products, and workstation 7 is the position for stacking and taking out finished products.

3. The unmanned welding system for prefabricated panels of a building according to claim 2 is characterized in that: The loading unit includes: a cement fiber substrate destacking robot and a hand gripper, a steel frame handling robot and a hand gripper, and a steel frame conveyor line. The cement fiber substrate destacking robot grabs the cement fiber substrate from the incoming material pallet and places it on the workstation 1 on the main conveyor line by means of a hand gripper. The main conveyor line conveys the cement fiber substrate from the workstation 1 to the workstation 2. The steel frame handling robot transports the steel frame from the steel frame conveyor line to the cement fiber substrate.

4. The unmanned welding system for prefabricated panels of a building according to claim 2 is characterized in that: The blocking mechanism comprises a motor and a blocking plate, the motor and the blocking plate are in transmission connection, and the motor and the blocking plate are arranged on the main conveying line; The forward push mechanism comprises a motor and a forward push plate, the motor and the forward push plate are in driving connection, and the motor drives the forward push plate to position the steel bar frame assembly onto the cement fiber substrate; The lifting support mechanism includes a hydraulic lifting device, which is arranged at workstations 3 and 4, and is installed below the bottom of the cement fiber substrate to support the bottom of the cement fiber substrate upwards; The workstation clamping mechanism includes multiple sets of clamping cylinders and a gantry fixing frame, multiple sets of clamping cylinders are fixedly arranged on the gantry fixing frame, multiple sets of clamping cylinders are located above the cement fiber base plate and the steel bar frame assembly, the clamping cylinder includes a cylinder and a cylinder push rod, and the cylinder is connected to the cylinder push rod; when the clamping cylinder is working, the cylinder push rod of the clamping cylinder presses down to contact the steel bar frame of the cement fiber base plate and the steel bar frame assembly, so that the steel bar frame is completely fitted with the cement fiber base plate surface.

5. The unmanned welding system for assembly line prefabricated building panels according to claim 4 is characterized in that: The 3D vision system includes multiple 3D industrial cameras and an industrial computer. The multiple 3D industrial cameras are respectively connected to the industrial computer and are respectively installed at different positions on the gantry fixed frame. The 3D industrial cameras are located above the steel frame and cement fiber substrate assembly.

6. The unmanned welding system for prefabricated panels of a building according to claim 5 is characterized in that: The automatic welding unit includes multiple welding robots, welding power supplies, and welding control systems. The welding robots are electrically connected to the welding power supplies and welding control systems respectively. The multiple welding robots are respectively arranged on both sides of the workstations 3 and 4 of the main conveyor line.

7. The unmanned welding system for prefabricated panels of a building according to claim 1 is characterized in that: The automatic palletizing unit includes a palletizing robot, a hand gripper, and a transfer table. The palletizing robot grabs qualified finished welded products from station 7 and palletizes them on a qualified pallet; puts qualified finished welded products that need to be flipped for palletizing on the transfer table, grabs them in reverse and palletizes them on a qualified pallet; and palletizes unqualified products on an unqualified pallet.

8. An unmanned welding method for assembly line prefabricated building panels, implemented based on an unmanned welding system for assembly line prefabricated building panels as claimed in any one of claims 1 to 7, characterized in that: include: S1, transporting the cement fiber substrate from the predetermined stack to the main conveyor line station 1 by the cement fiber substrate destacking robot, centering and positioning the cement fiber substrate at station 1, and continuing to transport the cement fiber substrate to the main conveyor line station 2 for blocking and positioning by the blocking mechanism; S2, transporting the steel frame from the steel frame conveyor line to the main conveyor line station 2 by a transport robot, and positioning the steel frame and the cement fiber substrate to form a cement fiber substrate and steel frame assembly by a forward push mechanism; S3, the mud fiber substrate and the steel frame assembly are transported to the main conveyor line station 3, the bottom of the mud fiber substrate is supported by water through the jacking support mechanism, and the steel frame is pressed on the cement fiber substrate through the station pressing mechanism, so that the steel frame and the cement fiber substrate surface are in contact; S4, taking photos of the relative positions of the steel frame and the iron holes on the cement fiber substrate through the 3D vision system; calculating the relative positions of the steel frame and the iron holes on the cement fiber substrate, and the 3D vision system transmits the avoidance hole coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel frame and the cement fiber substrate iron sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, and obtains the semi-finished product of the cement fiber substrate and the steel frame; S5, the semi-finished product of the semi-cement fiber substrate and the steel frame is transported to the main conveyor line station 4, and the steel frame and the cement fiber substrate iron sheet component are spot welded for the second time by the automatic welding unit according to the avoidance hole coordinates transmitted by the 3D vision system to obtain the finished product of the cement fiber substrate and the steel frame; S6. The finished products of the cement fiber substrate and the steel frame are transported to the main conveyor line stations 5 and 6, and the finished products of the welding are sampled to check whether they are qualified. The S7 palletizing robot grabs qualified finished welded products from station 7 and palletizes them on qualified pallets; it places qualified finished welded products that need to be flipped over for palletizing on the transfer table, grabs them in reverse and palletizes them on qualified pallets; it palletizes unqualified products on unqualified pallets.

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