Smooth aluminum sheath welding method

Abstract

The invention provides a smooth aluminum sheath welding method, and relates to the technical field of smooth aluminum sheath cable manufacturing, and the smooth aluminum sheath welding method comprises the following steps: S1, cleaning a to-be-welded smooth aluminum strip and a cable end; s2, the smooth aluminum strip and the cable end are conveyed to a wrapping mechanism through a feeding mechanism to be processed, and the smooth aluminum strip is curled into a tubular shape and wraps the outer surface of the cable; s3, welding treatment is conducted through a double-welding-gun mechanism, and welding sealing is conducted on a gap of the tubular smooth aluminum sheath; and S4, after welding is completed, the cable with the smooth surface and the welded aluminum sheath is conveyed to a cooling mechanism to be subjected to welding seam cooling treatment to the room temperature, and the welding seam is polished and cleaned. S5, meanwhile, the automatic monitoring system records and monitors the welding arc and welding seam conditions; s6, packaging treatment is carried out, a layer of heat-shrinkable sleeve is packaged at the weld joint firstly, and it is ensured that the weld joint is completely covered; the alternating current welding mode and the direct current welding mode of the double-welding-gun mechanism are cooperated, so that the continuity and the flatness of welding seams are improved.

Description

Technical Field

[0001] The invention relates to the technical field of smooth aluminum sheath cable manufacturing, in particular to a smooth aluminum sheath welding method. Background Art

[0002] The aluminum sheath of the smooth aluminum sheath cable needs to be in close contact with the water-blocking layer and the hot-melt adhesive layer. In addition, the thermal expansion and contraction of the cable after operation must be considered during production, which will lead to mutual extrusion between the layers, and place higher requirements on the flatness of the aluminum sheath weld. The smooth aluminum sheath is welded by argon arc welding. Considering the next step in aluminum sheath manufacturing - outer sheath extrusion, the machine cannot be stopped during the production of the entire cable reel, and the welding process must be of high level and high reliability.

[0003] Traditional corrugated aluminum sheaths are welded with a single welding gun using DC welding. The welding stability is relatively low and it is prone to welding leaks and cold welds. Manual repair welding is required. When the tungsten needle is severely worn, the machine needs to be stopped for replacement. It is difficult to achieve non-stop linkage with the three-layer co-extrusion of the outer sheath. In addition, the process defects of a single welding gun are more obvious. The concave at the weld cannot be effectively avoided, and the concave is prone to insulation. Summary of the invention

[0004] The present invention provides a smooth aluminum sheath welding method, which is used to solve at least one of the technical problems raised by the above background technology.

[0005] In order to solve the above technical problems, the present invention provides a smooth aluminum sheath welding method, comprising:

[0006] Step S1: Clean the smooth aluminum strip and cable end to be welded to ensure that the welding surface is clean and tidy;

[0007] Step S2: The smooth aluminum strip and the cable end are conveyed to the wrapping mechanism through the feeding mechanism, and the smooth aluminum strip is curled into a tube and wrapped around the cable surface;

[0008] Step S3: welding is performed by a double welding gun mechanism, using two aluminum welding rods to directly weld and seal the top gap of the tubular smooth aluminum strip to form a smooth aluminum sheath;

[0009] Step S4: After the welding is completed, the cable with the smooth aluminum sheath welded is transported to a cooling mechanism to cool the weld to room temperature, and the weld is polished and cleaned at the same time;

[0010] Step S5: while the welding process is in progress, the automatic monitoring system records and monitors the welding arc and weld conditions, and performs real-time monitoring of the weld after cooling;

[0011] Step S6: perform encapsulation processing, first encapsulate a layer of heat shrink tubing at the weld to ensure that the weld is completely covered, and then encapsulate a second layer of heat shrink tubing that is longer and evenly sealed on all sides to enhance the waterproof effect.

[0012] Preferably, the cleaning process in step S1 includes using a chemical cleaning agent and ultrasonic cleaning to improve the cleanliness of the surface of the aluminum sheath;

[0013] In the dual welding gun mechanism of the welding device in step S3, the main welding gun adopts an AC power supply, and the backup welding gun adopts a DC power supply, and the two work together to automatically adjust the welding parameters according to the welding process and real-time quality feedback.

[0014] Preferably, the cooling treatment in step S4 adopts staged cooling, the first stage of cooling adopts air supply cooling to the weld surface, and the second stage adopts circulating cooling water in a cooling water tank to infiltrate the weld for cooling, and the circulation rate of the circulating cooling water can be adjusted to control the cooling rate.

[0015] Preferably, the feeding mechanism in step S2 includes: a first bracket, the first bracket is fixedly installed on the right end of the bottom plate, the top of the first bracket is rotatably connected to an aluminum strip feeding roller in the front-to-back direction, the front end of the axis of the aluminum strip feeding roller is connected to the output shaft of motor one, and a second bracket is fixedly installed on the left bottom plate of the first bracket, the top of the second bracket is rotatably connected to a cable feeding roller in the front-to-back direction, and the front end of the axis of the cable feeding roller is connected to motor two.

[0016] Preferably, the aluminum strip flattening mechanism includes: a C-shaped bracket fixedly installed on the left side of the second bracket, a square tube fixedly installed in the left and right directions in the middle of the C-shaped bracket, the C-shaped bracket is symmetrically slidably connected to a pair of sliding vertical rods up and down, a spring 1 is provided on the outer sleeve of the sliding vertical rod, the sliding vertical rod is rotatably connected to the extrusion roller near the end of the square tube, the front end of the extrusion roller is fixedly connected to pulley 1, pulley 1 is connected to pulley 2 through a belt, pulley 2 is fixedly connected to the output shaft end of motor 3, and motor 3 is fixedly connected to the C-shaped bracket.

[0017] Preferably, the wrapping mechanism in step S2 includes: a wrapping platform, a wrapping platform in left and right directions fixedly installed on the top of the middle part of the bottom plate, a first sleeve, a second sleeve, a third sleeve and a fourth sleeve installed in sequence from right to left on the top of the wrapping platform, and the diameters of the first sleeve, the second sleeve, the third sleeve and the fourth sleeve gradually decrease.

[0018] Preferably, the dual welding gun mechanism in step S3 includes: a vertical screw mounting seat is fixedly installed on the top middle part of the base plate, a vertical lifting screw is rotatably connected in the screw mounting seat, the top of the lifting screw is fixedly connected to the output shaft end of the lifting motor, the lifting screw is threadedly connected to the threaded sleeve, the front end of the threaded sleeve is fixedly connected to the crossbeam 1, a pair of mounting frames are symmetrically installed on the left and right of the crossbeam 1, a distance sensor 1 is fixedly installed on the bottom end of the mounting frame, a first welding gun is fixedly installed on the right mounting frame, and a second welding gun is fixedly installed on the left mounting frame, the first welding gun is electrically connected to a DC power supply, and the second welding gun is electrically connected to an AC power supply.

[0019] Preferably, the automatic monitoring system in step S5 includes: a first monitoring mechanism and a second monitoring mechanism, two groups of symmetrical first monitoring mechanisms are fixedly provided on the crossbeam, the first monitoring mechanism on the left side includes a spur gear 1, the front end of the left side of the crossbeam 1 is rotatably connected to the spur gear 1, the spur gear 1 is meshed and connected to the spur gear 2, the spur gear 2 is fixedly connected to the output shaft of the servo motor, the first camera is fixedly installed at the bottom of the spur gear 1, and a photosensor is fixedly provided on the outside of the first camera; the second monitoring mechanism includes a slide rail, a left and right slide rail is fixedly installed at the left end of the middle part of the screw mounting seat, the top end of the slide rail is fixedly connected to the left and right linear racks, the slide rail is slidably connected to the slide seat, the pan-tilt camera is fixedly installed at the bottom of the slide seat, and the slide seat is powered by a driving mechanism 1 to achieve left and right sliding.

[0020] Preferably, a traction, extrusion and grinding mechanism is also provided, and the traction, extrusion and grinding mechanism comprises: a base, a base is fixedly installed on the top left side of the bottom plate, a rectangular frame is fixedly connected to the top of the base, and extrusion mechanisms are fixedly provided on the front and rear side walls and the top wall of the rectangular frame, and the extrusion mechanisms on the front and rear sides are symmetrical along the center of the rectangular frame, and the front extruder mechanism comprises: an L-shaped bracket is fixedly connected to the left side wall of the rectangular frame, an extrusion motor is fixedly installed on the front end of the L-shaped bracket, a lead screw two is rotatably connected to the front and rear directions between the L-shaped bracket and the rectangular frame, the front end of the lead screw two is fixedly connected to the output shaft of the extrusion motor, the top end of the lead screw two is fixedly connected to the vertical frame, the top of the rear side of the vertical frame is fixedly connected to the cross bar one, and the rear end of the cross bar one is fixedly connected to the rotating seat.

[0021] Preferably, the rotating seat is rotatably connected to the first vertical rotating roller, the top of the first rotating roller is fixedly connected to bevel gear one, bevel gear one is meshed with bevel gear two, the front end of bevel gear two is fixedly connected to the transmission shaft, the transmission shaft and cross bar one slide left and right respectively and pass through the front side wall of the rectangular frame, the right end of the transmission shaft is fixedly connected to the traction motor, and the traction motor is fixedly connected to the vertical frame; the right end of the rotating seat of the top extrusion mechanism is fixedly installed with sleeve three, the top of sleeve three is fixedly installed with a vertical grinding motor, the output shaft of the grinding motor is fixedly connected to the sanding disk, the bottom of the rectangular frame is fixedly connected to sleeve four, the sleeve four slides up and down inside and is connected to vertical frame one, the top of vertical frame one is rotatably connected to the second rotating roller, and vertical frame one is fixed in sleeve four by a limit bolt.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: the smooth aluminum sheath welding method provided by the present invention ensures the high quality of the welding surface through strict cleaning steps, laying a solid foundation for the subsequent welding process. The design of the feeding mechanism makes the conveying process of the smooth aluminum strip and the cable end smooth and accurate, ensuring the accurate placement of the welding materials. The adoption of the double welding gun mechanism not only improves the welding efficiency, but also significantly improves the welding quality and stability through the coordinated work of the main welding gun and the standby welding gun, and automatically adjusts the welding parameters according to the welding process and real-time quality feedback. The cooling mechanism adopts a staged cooling method to effectively control the cooling rate of the weld, avoid the stress and deformation caused by rapid cooling, and further ensure the welding quality. The introduction of the automatic monitoring system realizes real-time monitoring and recording of the entire welding process, and improves the safety and traceability of production. Finally, through the encapsulation treatment of the double-layer heat shrink tubing, the waterproof effect of the weld is enhanced and the service life of the cable is extended. In summary, the method of the present invention has the advantages of high efficiency, stability, reliability, safety, etc., and significantly improves the quality and efficiency of smooth aluminum sheath welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0024] Figure 1 It is a schematic diagram of a smooth aluminum sheath welding method of the present invention;

[0025] Figure 2 It is a front view schematic diagram of a supporting mechanism of a smooth aluminum sheath welding method of the present invention;

[0026] Figure 3 The present invention Figure 2 A magnified view of the local structure at center A;

[0027] Figure 4 The present invention Figure 2 A magnified view of the local structure at B in the middle;

[0028] Figure 5 It is a front view schematic diagram of the aluminum strip flattening mechanism of the present invention;

[0029] Figure 6 It is a right sectional schematic diagram of the traction, extrusion and grinding mechanism of the present invention.

[0030] Reference numerals:

[0031] 1. Feeding mechanism; 101. First bracket; 102. Bottom plate; 103. Aluminum strip feeding roller; 104. Motor 1; 105. Second bracket; 106. Motor 2; 107. Cable feeding roller; 2. Aluminum strip leveling mechanism; 201. C-shaped bracket; 202. Square tube; 203. Sliding vertical rod; 204. Spring 1; 205. Extrusion roller; 206. Pulley 1; 207. Pulley 2; 208. Belt; 209. Motor 3; 3. Wrapping mechanism; 30 1. Wrapping platform; 302. First casing; 303. Second casing; 304. Third casing; 305. Fourth casing; 4. Double welding gun mechanism; 401. Screw mounting seat; 402. Lifting screw; 403. Lifting motor; 404. Threaded sleeve; 405. Beam 1; 406. Mounting frame; 407. Distance sensor 1; 408. First welding gun; 409. Second welding gun; 410. DC power supply; 411. AC power supply; 5. Automatic monitoring system ; 510, first monitoring mechanism; 511, spur gear one; 512, spur gear two; 513, servo motor; 514, first camera; 515, photosensitive sensor; 520, second monitoring mechanism; 521, slide rail; 522, linear rack; 523, slide seat; 524, drive motor; 525, pulley three; 526, pulley four; 527, spur gear three; 528, pan / tilt camera; 6, traction extrusion grinding mechanism; 601, limit bolt; 60 2. Base; 603. Rectangular frame; 604. L-shaped bracket; 605. Extrusion motor; 606. Lead screw 2; 607. Vertical frame; 608. Crossbar 1; 609. Rotating seat; 610. First rotating roller; 611. Bevel gear 1; 612. Bevel gear 2; 613. Transmission shaft; 614. Traction motor; 615. Sleeve 3; 616. Grinding motor; 617. Sanding disc; 618. Sleeve 4; 619. Vertical frame 1; 620. Second rotating roller. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0034] In addition, in the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes, and do not specifically refer to the order or sequence, nor are they used to limit the present invention. They are only used to distinguish components or operations described with the same technical terms, and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions and technical features between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0035] The present invention provides the following embodiments

[0036] Embodiment 1, the embodiment of the present invention provides a smooth aluminum sheath welding method, such as Figure 1 As shown, it includes: step S1: cleaning the smooth aluminum strip and the cable end to be welded to remove oil stains, impurities, etc. on the surface to ensure that the welding surface is clean and tidy;

[0037] Step S2: The smooth aluminum strip and the cable end are conveyed to the wrapping mechanism 3 for processing by the feeding mechanism 1, and the smooth aluminum strip is curled into a tube and wrapped around the cable surface;

[0038] Step S3: performing welding processing by using the double welding gun mechanism 4, using two aluminum welding rods to directly weld and seal the top gap of the tubular smooth aluminum strip to form a smooth aluminum sheath;

[0039] Step S4: After the welding is completed, the cable with the smooth aluminum sheath welded is transported to a cooling mechanism to cool the weld to room temperature, and the weld is polished and cleaned at the same time;

[0040] Step S5: while the welding process is in progress, the automatic monitoring system 5 records and monitors the welding arc and weld conditions, and performs real-time monitoring of the weld after cooling;

[0041] Step S6: perform encapsulation processing, first encapsulate a layer of heat shrink tubing at the weld to ensure that the weld is completely covered, and then encapsulate a second layer of heat shrink tubing that is longer and evenly sealed on all sides to enhance the waterproof effect.

[0042] Preferably, the cleaning process in step S1 includes using a chemical cleaning agent and ultrasonic cleaning to improve the cleanliness of the surface of the aluminum sheath;

[0043] In the step S3, the dual welding gun mechanism 4 of the welding device uses an AC power supply 411 for the main welding gun and a DC power supply 410 for the backup welding gun, and the two work together to automatically adjust welding parameters according to the welding process and real-time quality feedback.

[0044] Preferably, the cooling treatment in step S4 adopts staged cooling, the first stage of cooling adopts air supply cooling to the weld surface, and the second stage adopts circulating cooling water in a cooling water tank to infiltrate the weld for cooling, and the circulation rate of the circulating cooling water can be adjusted to control the cooling rate.

[0045] The working principle and beneficial effects of the above technical scheme are as follows: the smooth aluminum sheath welding method provided by the present invention ensures the high quality of the welding surface through strict cleaning steps, laying a solid foundation for the subsequent welding process. The design of the feeding mechanism 1 makes the conveying process of the smooth aluminum strip and the cable end smooth and accurate, ensuring the accurate placement of the welding materials. The adoption of the double welding gun mechanism 4 not only improves the welding efficiency, but also significantly improves the welding quality and stability through the coordinated work of the main welding gun and the standby welding gun, and automatically adjusts the welding parameters according to the welding process and real-time quality feedback. The cooling mechanism adopts a staged cooling method to effectively control the cooling rate of the weld, avoid the stress and deformation caused by rapid cooling, and further ensure the welding quality. The introduction of the automatic monitoring system 5 realizes real-time monitoring and recording of the entire welding process, and improves the safety and traceability of production. Finally, through the encapsulation treatment of the double-layer heat shrink tubing, the waterproof effect of the weld is enhanced and the service life of the cable is extended. In summary, the method of the present invention has the advantages of high efficiency, stability, reliability, and safety, and significantly improves the quality and efficiency of smooth aluminum sheath welding.

[0046] Embodiment 2, on the basis of embodiment 1, as Figure 2 , Figure 5 As shown, the welding device in steps S2-S5 includes: a base plate 102, a feeding mechanism 1, a wrapping mechanism 3, a dual welding gun mechanism 4 and an automatic monitoring system 5. The feeding mechanism 1 is fixedly provided on the top right side of the base plate 102, the wrapping mechanism 3 is fixedly provided on the left output end of the feeding structure, the dual welding gun mechanism 4 is fixedly provided on the top of the wrapping mechanism 3, and the automatic monitoring system 5 is fixedly provided on the dual welding gun mechanism 4.

[0047] The feeding mechanism 1 in step S2 includes: a first bracket 101, the first bracket 101 is fixedly installed on the right end of the bottom plate 102, the top of the first bracket 101 is rotatably connected to the aluminum strip feeding roller 103 in the front-to-back direction, the front end of the axis of the aluminum strip feeding roller 103 is connected to the output shaft of motor 1 104, and a second bracket 105 is fixedly installed on the left bottom plate 102 of the first bracket 101, the top of the second bracket 105 is rotatably connected to the cable feeding roller 107 in the front-to-back direction, and the front end of the axis of the cable feeding roller 107 is connected to motor 2 106.

[0048] The aluminum strip flattening mechanism 2 includes: a C-shaped bracket 201 is fixedly installed on the left side of the second bracket 105, a square tube 202 is fixedly installed in the middle of the C-shaped bracket 201 in the left and right directions, the C-shaped bracket 201 is symmetrically slidably connected to a pair of sliding vertical rods 203 up and down, the outer sleeve of the sliding vertical rod 203 is provided with a spring 1 204, the sliding vertical rod 203 is rotatably connected to the end of the square tube 202 and connected to the extrusion roller 205, the front end of the extrusion roller 205 is fixedly connected to the pulley 1 206, the pulley 1 206 is connected to the pulley 2 207 through a belt 208, the pulley 207 is fixedly connected to the output shaft end of the motor 3 209, and the motor 3 209 is fixedly connected to the C-shaped bracket 201.

[0049] The wrapping mechanism 3 in step S2 includes: a wrapping platform 301, a wrapping platform 301 fixedly installed on the top of the middle part of the bottom plate 102 in the left and right directions, a first sleeve 302, a second sleeve 303, a third sleeve 304 and a fourth sleeve 305 are installed on the top of the wrapping platform 301 in sequence from right to left, and the diameters of the first sleeve 302, the second sleeve 303, the third sleeve 304 and the fourth sleeve 305 are gradually reduced.

[0050] The working principle and beneficial effects of the above technical solution are as follows: when the feeding mechanism 1 is in operation, the motor 104 drives the aluminum strip feeding roller 103 to rotate and deliver the aluminum strip to the aluminum strip flattening mechanism 2. When the aluminum strip flattening mechanism 2 is in operation, the upper and lower symmetrical springs 204 squeeze the upper and lower squeezing rollers 205 toward the center aluminum strip under the action of elastic force. At the same time, the upper motor 3 209 rotates clockwise, and the lower motor 3 209 rotates counterclockwise, thereby causing the upper and lower pulleys 206 to rotate relative to each other. The pulley 206 passes through The belt 208 makes the pulley 207 and the squeezing roller 205 rotate synchronously and relatively. The upper and lower squeezing rollers 205 rotate relatively to transport the aluminum strip to the left, pass through the square tube 202 and enter the wrapping mechanism 3. The motor 2 106 starts to run and drives the cable feeding roller 107 on the top of the second bracket 105 to rotate and transport the cable to the wrapping mechanism 3. The diameter of the wrapping mechanism 3 is gradually reduced through the first sleeve 302, the second sleeve 303, the third sleeve 304 and the fourth sleeve 305, so that the aluminum strip gradually bends upward to wrap the cable.

[0051] Based on Example 1, this embodiment further refines the structural design of the welding device. The feeding mechanism 1 realizes the synchronous conveying of the smooth aluminum strip and the cable end through double brackets and motor drive, and the conveying process is smooth and reliable. The aluminum strip flattening mechanism 2 effectively ensures the flatness of the aluminum strip and the accuracy of feeding through the synergistic effect of components such as the sliding vertical rod 203, the spring, and the extrusion roller 205. The design of the wrapping mechanism 3 realizes the gradual wrapping of the cable by the smooth aluminum strip through a gradually reduced sleeve, ensuring the tightness and uniformity of the wrapping. These design improvements not only improve the overall performance of the welding device, but also further improve the welding quality and efficiency. At the same time, the integration of the welding device and the automatic monitoring system 5 makes the entire welding process more automated and intelligent, reduces the need for manual intervention, and improves production efficiency and stability.

[0052] Embodiment 3, on the basis of embodiment 1, as Figure 2-Figure 4 As shown, the double welding gun mechanism 4 in step S3 includes: a vertical screw mounting seat 401 is fixedly installed at the top of the middle part of the base plate 102, a vertical lifting screw 402 is rotatably connected in the screw mounting seat, the top of the lifting screw 402 is fixedly connected to the output shaft end of the lifting motor 403, the lifting screw 402 is threadedly connected to the threaded sleeve 404, the front end of the threaded sleeve 404 is fixedly connected to the cross beam 1 405, a pair of mounting frames 406 are symmetrically installed on the cross beam 1 405, a distance sensor 1 407 is fixedly installed on the bottom end of the mounting frame 406, a first welding gun 408 is fixedly installed on the right mounting frame 406, and a second welding gun 409 is fixedly installed on the left mounting frame 406, the first welding gun 408 is electrically connected to the DC power supply 410, and the second welding gun 409 is electrically connected to the AC power supply 411.

[0053] The automatic monitoring system 5 in step S5 includes: a first monitoring mechanism 510 and a second monitoring mechanism 520. Two groups of symmetrical first monitoring mechanisms 510 are fixed on the crossbeam. The first monitoring mechanism 510 on the left side includes a spur gear 1 511. The front end of the left side of the crossbeam 1 405 is rotatably connected to the spur gear 1 511. The spur gear 1 511 is meshed and connected to the spur gear 2 512. The spur gear 2 512 is fixedly connected to the output shaft of the servo motor 513. The first camera 514 is fixedly installed at the bottom of the spur gear 1 511. A light sensor 515 is fixedly installed outside the first camera 514. The second monitoring mechanism 520 includes a slide rail 521. The left end of the middle part of the screw mounting seat 401 is fixedly installed with a left and right slide rail 521. The top of the slide rail 521 is fixedly connected to a left and right linear rack 522. The slide rail 521 is slidably connected to a slide seat 523. A pan / tilt camera 528 is fixedly installed at the bottom of the slide seat 523. The slide seat 523 is powered by a driving mechanism 1 to achieve left and right sliding.

[0054] The driving mechanism 1 includes: a driving motor 524 is fixedly installed on the top of the slide 523, the output shaft of the driving motor 524 is fixedly connected to the pulley 3 525, the pulley 3 525 is connected to the pulley 4 526 through the belt 208, the pulley 4 526 is rotatably connected to the slide 523, and the rear end of the pulley 4 526 is fixedly connected to the spur gear 3 527, and the spur gear 3 527 is meshed and connected with the linear rack 522.

[0055] The working principle and beneficial effects of the above technical solution are as follows: when the double welding gun mechanism 4 is working, the lifting motor 403 runs to drive the lifting screw 402 to rotate, and the lifting screw 402 rotates to make the threaded sleeve 404 and the crossbeam 1 405 slide downward synchronously, and the distance sensor 1 407 is responsible for detecting the distance between the first welding gun 408 and the second welding gun 409 and the welding smooth aluminum, which is convenient for real-time adjustment; at the same time, the automatic monitoring system 5 first runs the first monitoring mechanism 510, and the servo motor 513 runs to drive the spur gear 1 511 to rotate, and the spur gear 1 511 meshes and drives so that the spur gear 2 512 and the first camera 514 or the second camera adjust the angle to the direction of the welding point, so as to monitor the welding arc at the welding point in real time, and the first camera 51 4 or the second camera surface is provided with a dark filter, the photosensitive sensor 515 provides tracking of the welding arc angle direction, the first camera 514 or the second camera uploads the image information to the cloud, the operator accesses the cloud to obtain monitoring information, and at the same time the pan / tilt camera 528 of the second monitoring mechanism 520 is responsible for sliding left and right to monitor the appearance of the weld after welding; when the slide 523 needs to slide, the drive motor 524 drives the pulley three 525 to rotate, the pulley three 525 is driven by the belt 208 to make the pulley four 526 and the spur gear three 527 rotate synchronously, the spur gear three 527 rotates on the linear rack 522 to push the slide 523 to slide left and right on the slide rail 521, and the weld is reciprocated to detect whether there is leakage or broken welding;

[0056] Based on Example 1, this embodiment focuses on optimizing the design of the dual welding gun mechanism 4 and the automatic monitoring system 5. The dual welding gun mechanism 4 realizes the height and position adjustment of the welding gun through the precise cooperation of the lifting screw 402, the threaded sleeve 404, the crossbeam 405 and other components, so that it can be accurately controlled according to the welding requirements. At the same time, the coordinated work of the main welding gun and the standby welding gun, as well as the function of automatically adjusting the welding parameters according to the welding process and real-time quality feedback, further improve the welding quality and stability. The automatic monitoring system 5 realizes all-round real-time monitoring and recording of the welding process through the dual monitoring of the first monitoring mechanism 510 and the second monitoring mechanism 520. The first monitoring mechanism 510 can clearly capture the detailed changes in the welding process through the cooperation of the camera and the photosensitive sensor 515; the second monitoring mechanism 520 realizes flexible monitoring of the welding area through the linkage of the slide rail 521, the slide seat 523, the pulley and other components. These design improvements not only improve the automation and intelligence level of the welding process, but also enhance the safety and traceability of production.

[0057] Embodiment 4, on the basis of embodiment 1, as Figure 2 , Figure 6 As shown, a traction, extrusion and grinding mechanism 6 is also provided, and the traction, extrusion and grinding mechanism 6 includes: a base 602, the base 602 is fixedly installed on the top left side of the bottom plate 102, the top of the base 602 is fixedly connected to a rectangular frame 603, the front and rear side walls and the top wall of the rectangular frame 603 are fixedly fixed with extrusion mechanisms, and the extrusion mechanisms on the front and rear sides are symmetrical along the center of the rectangular frame 603, and the front extruder mechanism includes: the left side wall of the rectangular frame 603 is fixedly connected to an L-shaped bracket 604, the front end of the L-shaped bracket 604 is fixedly installed with an extrusion motor 605, the middle of the L-shaped bracket 604 and the rectangular frame 603 is rotatably connected to a lead screw 2 606 in the front and rear directions, the front end of the lead screw 2 606 is fixedly connected to the output shaft of the extrusion motor 605, the top of the lead screw 2 606 is fixedly connected to a stand 607, the top of the rear side of the stand 607 is fixedly connected to a cross bar 1 608, and the rear end of the cross bar 1 608 is fixedly connected to a rotating seat 609.

[0058] The rotating seat 609 is rotatably connected to the vertical first rotating roller 610, the top of the first rotating roller 610 is fixedly connected to the bevel gear 1 611, the bevel gear 1 611 is meshed with the bevel gear 2 612, the front end of the bevel gear 2 612 is fixedly connected to the transmission shaft 613, the transmission shaft 613 and the cross bar 1 608 slide left and right respectively and penetrate the front side wall of the rectangular frame 603, the right end of the transmission shaft 613 is fixedly connected to the traction motor 614, and the traction motor 614 is fixedly connected to the vertical frame 607; the right end of the rotating seat 609 of the top extrusion mechanism is fixedly installed with the sleeve 3 615, the top of the sleeve 3 615 is fixedly installed with the vertical grinding motor 616, the output shaft of the grinding motor 616 is fixedly connected to the grinding disk 617, the bottom of the rectangular frame 603 is fixedly connected to the sleeve 4 618, the sleeve 4 618 is slid up and down inside the vertical frame 1 619, the top of the vertical frame 1 619 is rotatably connected to the second rotating roller 620, and the vertical frame 1 619 is fixed in the sleeve 4 618 by the limiting bolt 601.

[0059] The working principle and beneficial effects of the above technical solution are as follows: when the traction extrusion grinding mechanism 6 is working, after the smooth aluminum cable is welded, the smooth aluminum and the cable are tightly extruded and fitted together through the traction extrusion grinding mechanism 6, and the cable is pulled to the next process at the same time. First, the extrusion motor 605 runs to drive the second screw 606 to rotate. The rotation of the second screw 606 drives the stand 607, the cross bar 1 608, the rotating seat 609 and the first rotating roller 610 to slide toward the center until the front and rear and top extrusion rollers 205 press the surface of the smooth aluminum sheath of the cable. At this time, the traction motor 614 rotates to drive the transmission shaft 613 and the second bevel gear 612 to rotate. The second bevel gear 612 drives the first bevel gear 611 and the first rotating roller 610 to rotate synchronously, extruding the cable and traction it to the left for transportation. At the same time, the top grinding motor 616 runs to drive the grinding disc to grind and polish the top weld of the cable to make the weld smoother.

[0060] Based on Example 1, this embodiment adds a traction, extrusion and grinding mechanism 6 to further improve the post-welding processing effect. The mechanism realizes the traction, extrusion and grinding of the cable after welding through the precise coordination of the traction motor 614, the extrusion motor 605, the lead screw 606, the bevel gear and other components. The coordinated work of the traction motor 614 and the extrusion motor 605 ensures the stability and consistency of the cable during the traction process; the transmission of the lead screw 606 and the bevel gear realizes the precise extrusion and positioning of the cable. The introduction of the grinding motor 616 grinds the weld through the grinding disc 617, removes the burrs and uneven parts generated during the welding process, and further improves the flatness and aesthetics of the weld. These design improvements not only improve the processing efficiency and quality after welding, but also extend the service life and reliability of the cable.

[0061] 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, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A smooth aluminum sheath welding method, characterized in that: include: Step S1: Clean the smooth aluminum strip and cable end to be welded to ensure that the welding surface is clean and tidy; Step S2: The smooth aluminum strip and the cable end are conveyed to the wrapping mechanism (3) through the feeding mechanism (1) for processing, and the smooth aluminum strip is curled into a tube and wrapped around the cable surface; Step S3: welding is performed by using a double welding gun mechanism (4) to weld the top gap of the tubular smooth aluminum strip by directly welding two aluminum welding rods to form a smooth aluminum sheath; Step S4: After the welding is completed, the cable with the smooth aluminum sheath welded is transported to a cooling mechanism to cool the weld to room temperature, and the weld is polished and cleaned at the same time; Step S5: while the welding process is in progress, the automatic monitoring system (5) records and monitors the welding arc and weld conditions, and performs real-time monitoring of the weld after cooling; Step S6: perform encapsulation processing, first encapsulate a layer of heat shrink tubing at the weld to ensure that the weld is completely covered, and then encapsulate a second layer of heat shrink tubing that is longer and evenly sealed on all sides to enhance the waterproof effect.

2. A smooth aluminum sheath welding method according to claim 1, characterized in that: The cleaning process in step S1 includes using a chemical cleaning agent and ultrasonic cleaning to improve the cleanliness of the surface of the aluminum sheath; In the dual welding gun mechanism (4) of the welding device in step S3, the main welding gun adopts an AC power supply (411) and the backup welding gun adopts a DC power supply (410), and the two work together to automatically adjust welding parameters according to the welding process and real-time quality feedback.

3. A smooth aluminum sheath welding method according to claim 1, characterized in that: The cooling process in step S4 adopts staged cooling. The first stage of cooling adopts air supply cooling to the weld surface, and the second stage adopts circulating cooling water in the cooling water tank to infiltrate the weld for cooling. The circulation rate of the circulating cooling water can be adjusted to control the cooling rate.

4. A smooth aluminum sheath welding method according to claim 1, characterized in that: The feeding mechanism (1) in step S2 comprises: a first bracket (101), the first bracket (101) is fixedly mounted on the right end of the bottom plate (102), the top of the first bracket (101) is rotatably connected to an aluminum strip feeding roller (103) in the front-to-back direction, the front end of the axis of the aluminum strip feeding roller (103) is connected to the output shaft of a motor 1 (104), a second bracket (105) is fixedly mounted on the left bottom plate (102) of the first bracket (101), the top of the second bracket (105) is rotatably connected to a cable feeding roller (107) in the front-to-back direction, and the front end of the axis of the cable feeding roller (107) is connected to a motor 2 (106).

5. A smooth aluminum sheath welding method according to claim 4, characterized in that: The aluminum strip leveling mechanism (2) comprises: a C-shaped bracket (201), the C-shaped bracket (201) is fixedly installed on the left side of the second bracket (105), a square tube (202) in the left and right directions is fixedly installed in the middle of the C-shaped bracket (201), the C-shaped bracket (201) is symmetrically slidably connected to a pair of sliding vertical rods (203) in the upper and lower directions, the outer sleeve of the sliding vertical rod (203) is provided with a spring 1 (204), the sliding vertical rod (203) is rotatably connected to the end close to the square tube (202) to connect to the squeezing roller (205), the front end of the squeezing roller (205) is fixedly connected to the pulley 1 (206), the pulley 1 (206) and the pulley 2 (207) are connected by a belt (208), the pulley 2 (207) is fixedly connected to the output shaft end of the motor 3 (209), and the motor 3 (209) is fixedly connected to the C-shaped bracket (201).

6. A smooth aluminum sheath welding method according to claim 4, characterized in that: The wrapping mechanism (3) in step S2 comprises: a wrapping platform (301), the wrapping platform (301) being fixedly installed on the top of the middle part of the bottom plate (102) in the left and right directions, the top of the wrapping platform (301) being installed with a first sleeve (302), a second sleeve (303), a third sleeve (304) and a fourth sleeve (305) in sequence from right to left, and the diameters of the first sleeve (302), the second sleeve (303), the third sleeve (304) and the fourth sleeve (305) being gradually reduced.

7. A smooth aluminum sheath welding method according to claim 4, characterized in that: The dual welding gun mechanism (4) in step S3 comprises: a vertical screw mounting seat (401) is fixedly installed at the top of the middle part of the base plate (102), a vertical lifting screw (402) is rotatably connected inside the screw mounting seat, the top of the lifting screw (402) is fixedly connected to the output shaft end of the lifting motor (403), the lifting screw (402) is threadedly connected to a threaded sleeve (404), the front end of the threaded sleeve (404) is fixedly connected to a cross beam (405), a pair of mounting frames (406) are symmetrically installed on the left and right of the cross beam (405), a distance sensor (407) is fixedly installed at the bottom end of the mounting frame (406), a first welding gun (408) is fixedly installed on the right mounting frame (406), and a second welding gun (409) is fixedly installed on the left mounting frame (406), the first welding gun (408) is electrically connected to a DC power supply (410), and the second welding gun (409) is electrically connected to an AC power supply (411).

8. A smooth aluminum sheath welding method according to claim 7, characterized in that: The automatic monitoring system (5) in step S5 comprises: a first monitoring mechanism (510) and a second monitoring mechanism (520), two groups of symmetrical first monitoring mechanisms (510) are fixedly arranged on the crossbeam, the first monitoring mechanism (510) on the left side comprises a spur gear 1 (511), the front end of the left side of the crossbeam 1 (405) is rotatably connected to the spur gear 1 (511), the spur gear 1 (511) is meshedly connected to the spur gear 2 (512), the spur gear 2 (512) is fixedly connected to the output shaft of the servo motor (513), and the bottom of the spur gear 1 (511) is fixed. A first camera (514) is installed, and a light-sensitive sensor (515) is fixedly provided on the outside of the first camera (514); the second monitoring mechanism (520) includes a slide rail (521), and the left end of the middle part of the lead screw mounting seat (401) is fixedly installed with the slide rail (521) in the left and right directions, and the top of the slide rail (521) is fixedly connected to the left and right linear rack (522), and the slide rail (521) is connected to the slide seat (523) in a left and right sliding manner, and a pan-tilt camera (528) is fixedly installed on the bottom of the slide seat (523), and the slide seat (523) is powered by a driving mechanism to achieve left and right sliding.

9. A smooth aluminum sheath welding method according to claim 4, characterized in that: A traction extrusion grinding mechanism (6) is also provided, and the traction extrusion grinding mechanism (6) comprises: a base (602), the base (602) is fixedly installed on the top of the left side of the bottom plate (102), the top of the base (602) is fixedly connected to a rectangular frame (603), the front and rear side walls and the top wall of the rectangular frame (603) are fixedly provided with extrusion mechanisms, and the extrusion mechanisms on the front and rear sides are symmetrical along the center of the rectangular frame (603), and the extrusion mechanism on the front side comprises: the left side wall of the rectangular frame (603) is fixedly connected to an L-shaped The bracket (604) is fixedly mounted with an extrusion motor (605) at the front end of the L-shaped bracket (604). A lead screw (606) is rotatably connected to the front-rear direction between the L-shaped bracket (604) and the rectangular frame (603). The front end of the lead screw (606) is fixedly connected to the output shaft of the extrusion motor (605). The top end of the lead screw (606) is fixedly connected to a stand (607). The top of the rear side of the stand (607) is fixedly connected to a cross bar (608). The rear end of the cross bar (608) is fixedly connected to a rotating seat (609).

10. A smooth aluminum sheath welding method according to claim 9, characterized in that: include: The rotating seat (609) is rotatably connected to a vertical first rotating roller (610); the top of the first rotating roller (610) is fixedly connected to a bevel gear 1 (611); the bevel gear 1 (611) is meshedly connected to a bevel gear 2 (612); the front end of the bevel gear 2 (612) is fixedly connected to a transmission shaft (613); the transmission shaft (613) and the cross bar 1 (608) respectively slide left and right and penetrate the front side wall of the rectangular frame (603); the right end of the transmission shaft (613) is fixedly connected to a traction motor (614); and the traction motor (614) is fixedly connected to the vertical frame (607); the top The right end of the rotating seat (609) of the extrusion mechanism is fixedly installed with a sleeve three (615), and a vertical grinding motor (616) is fixedly installed on the top of the sleeve three (615). The output shaft of the grinding motor (616) is fixedly connected to a grinding disk (617). The bottom of the rectangular frame (603) is fixedly connected to a sleeve four (618), and the sleeve four (618) is slidably connected to a vertical frame one (619) in an up-and-down manner. The top of the vertical frame one (619) is rotatably connected to a second rotating roller (620), and the vertical frame one (619) is fixed in the sleeve four (618) by a limiting bolt (601).

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