A method of welding a smooth aluminium sheath

Abstract

The present application provides a kind of smooth aluminum sheath welding method, it is related to smooth aluminum sheath cable manufacturing technical field, comprising: step S1: the smooth aluminum strip and cable end to be welded are cleaned and handled;Step S2: by feeding mechanism, smooth aluminum strip and cable end are transported to wrapping mechanism processing, and smooth aluminum strip is curled into tubular and wrapped to the outer surface of cable;Step S3: by double welding torch mechanism, the gap of tubular smooth aluminum sheath is welded and sealed;Step S4: after welding, the cable of surface smooth aluminum sheath welding completion is transported to cooling mechanism and is cooled to room temperature, and the weld is polished and cleaned.Step S5: simultaneously, automatic monitoring system records and monitors welding arc and weld condition;Step S6: packaging is handled, first a layer of heat shrinkable sleeve is packaged at weld, to ensure that weld is completely covered;The present application is synergized by alternating current and direct current welding mode of double welding torch mechanism, improves the continuity and flatness of weld.

Description

Technical Field

[0001] This invention relates to the field of smooth aluminum sheath cable manufacturing technology, and in particular to a smooth aluminum sheath welding method. Background Technology

[0002] The aluminum sheath of a smooth aluminum-sheathed cable needs to be in tight contact with the water-blocking layer and the hot melt adhesive layer. Furthermore, during production, the thermal expansion and contraction of the cable during operation, leading to mutual compression between the layers, places higher demands on the flatness of the aluminum sheath welds. The smooth aluminum sheath is welded using argon arc welding. Considering the next step in aluminum sheath manufacturing—outer sheath extrusion—the production process cannot be stopped during the entire cable reel production process, requiring a high level of skill and high reliability in the welding process.

[0003] Traditional corrugated aluminum sheaths are welded using a single welding gun with DC welding, which results in relatively low welding stability and is prone to issues such as missed welds and incomplete welds. Manual repair welding is required, and the tungsten needle needs to be replaced when it is severely worn. It is difficult to achieve non-stop linkage with the three-layer co-extrusion of the outer sheath, and the single welding gun process has obvious defects. The concave part of the weld seam cannot be effectively avoided, and the concave part is prone to insulation damage. Summary of the Invention

[0004] The present invention provides a smooth aluminum sheath welding method to solve at least one of the technical problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the present invention provides a method for welding smooth aluminum sheaths, 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 cable end are conveyed to the wrapping mechanism by the feeding mechanism. The smooth aluminum strip is rolled into a tube and wrapped around the cable.

[0008] Step S3: Welding is performed using a dual welding gun mechanism, employing two types of aluminum welding rods for direct welding, to seal the top gap of the tubular smooth aluminum strip and form a smooth aluminum sheath.

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

[0010] Step S5: Simultaneously, during the welding process, the automatic monitoring system records and monitors the welding arc and weld condition, and performs real-time monitoring of the cooled weld.

[0011] Step S6: encapsulation treatment is carried out, a layer of heat shrink sleeve is encapsulated at the weld first, to ensure that the weld is completely covered, and then a second layer of heat shrink sleeve is encapsulated, which is longer in length and is uniformly encapsulated on all sides, to enhance the waterproof effect.

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

[0013] The double-welding gun mechanism of the welding device in the step S3, the main welding gun uses alternating current power supply, and the backup welding gun uses direct current power supply, both of which work cooperatively, automatically adjust the welding parameters according to the welding process and real-time quality feedback.

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

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

[0016] Preferably, the aluminum strip flattening mechanism includes: a C-shaped support is fixedly installed on the left side of the second support, a square tube in the left-and-right direction is fixedly installed in the middle of the C-shaped support, a pair of sliding vertical rods are symmetrically and slidably connected to the C-shaped support, a spring one is arranged on the sliding vertical rod, an extrusion roller is rotatably connected to the end of the sliding vertical rod close to the square tube, a pulley one is fixedly connected to the front end of the extrusion roller, the pulley one and a pulley two are connected through a belt, the pulley two is fixedly connected with the output shaft end of the motor three, and the motor three is fixedly connected with the C-shaped support.

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

[0018] Preferably, the double-welding gun mechanism in step S3 comprises: a vertical screw rod mounting seat fixedly installed at the top of the middle part of the base plate, a vertical lifting screw rod rotationally connected in the screw rod mounting seat, the top end of the lifting screw rod fixedly connected with the output shaft end of a lifting motor, the lifting screw rod threadedly connected with a threaded sleeve, the front end of the threaded sleeve fixedly connected with a cross beam one, a pair of mounting brackets symmetrically installed on the cross beam one, a distance sensor one fixedly installed at the bottom end of the mounting bracket, a first welding gun fixedly installed on the right mounting bracket, a second welding gun fixedly installed on the left mounting bracket, the first welding gun electrically connected with a direct current power supply, and the second welding gun electrically connected with an alternating current power supply.

[0019] Preferably, the automatic monitoring system in step S5 comprises: a first monitoring mechanism and a second monitoring mechanism, the cross beam is fixedly provided with two groups of symmetric first monitoring mechanisms, the left first monitoring mechanism comprises a straight gear one, the left front end of the cross beam one is rotationally connected with the straight gear one, the straight gear one is meshingly connected with a straight gear two, the straight gear two is fixedly connected with the output shaft of a servo motor, the first camera is fixedly installed at the bottom of the straight gear one, and a photosensitive sensor is fixedly arranged outside the first camera; the second monitoring mechanism comprises a slide rail, the slide rail is fixedly installed at the left end of the middle part of the screw rod mounting seat in the left-right direction, the top end of the slide rail is fixedly connected with a left-right direction straight rack, the slide rail is slidably connected with a sliding seat in the left-right direction, the sliding seat is fixedly installed with a holder camera at the bottom, and the sliding seat is powered by a driving mechanism one to realize left-right sliding.

[0020] Preferably, the traction extrusion polishing mechanism is further provided, and the traction extrusion polishing mechanism comprises: a base, the base is fixedly installed at the top of the left side of the base plate, the top of the base is fixedly connected with a rectangular frame, the front and back side walls and the top wall of the rectangular frame are all fixedly provided with extrusion mechanisms, the extrusion mechanisms on the front and back sides are symmetric along the center of the rectangular frame, the extrusion mechanism on the front side comprises: the left side wall of the rectangular frame is fixedly connected with an L-shaped support, the L-shaped support is fixedly installed with an extrusion motor at the front end, the L-shaped support is rotationally connected with a second screw rod in the front-back direction at the middle part of the rectangular frame, the front end of the second screw rod is fixedly connected with the output shaft of the extrusion motor, the top end of the second screw rod is fixedly connected with a stand, the top of the back side of the stand is fixedly connected with a horizontal rod one, and the back end of the horizontal rod one is fixedly connected with a rotary seat.

[0021] Preferably, the rotary seat is rotationally connected with a vertical first rotary roller, the top of the first rotary roller is fixedly connected with a bevel gear one, the bevel gear one is meshingly connected with a bevel gear two, the front end of the bevel gear two is fixedly connected with a transmission shaft, the transmission shaft and the horizontal rod one respectively slidably penetrate through the front side wall of the rectangular frame in the left-right direction, the right end of the transmission shaft is fixedly connected with a traction motor, the traction motor is fixedly connected with the stand, the right end of the rotary seat of the top extrusion mechanism is fixedly installed with a sleeve three, the top of the sleeve three is fixedly installed with a vertical polishing motor, the output shaft of the polishing motor is fixedly connected with a sanding disc, the bottom of the rectangular frame is fixedly connected with a sleeve four, a vertical stand one is slidably connected in the sleeve four, the top of the vertical stand one is rotationally connected with a second rotary roller, and the vertical stand one is fixed in the sleeve four through a limiting bolt.

[0022] Compared with the prior art, the smooth aluminum sheath welding method provided by the application has the beneficial effects that the strict cleaning treatment steps ensure the high quality of the welding surface, 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 stable and accurate, ensuring the accurate placement of the welding material. 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 cooperative work of the main welding gun and the backup welding gun and the automatic adjustment of the welding parameters according to the welding process and real-time quality feedback. The cooling mechanism adopts a staged cooling method, effectively controlling the cooling rate of the weld, avoiding stress and deformation caused by rapid cooling, and further ensuring the welding quality. The introduction of the automatic monitoring system realizes real-time monitoring and recording of the whole welding process, improving the safety and traceability of production. Finally, through the packaging treatment of the double-layer heat shrink sleeve, the waterproof effect of the weld is enhanced, and the service life of the cable is prolonged. In summary, the method of the application has the advantages of high efficiency, stability, reliability, safety and the like, significantly improving the quality and efficiency of smooth aluminum sheath welding. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0024] Figure 1 is a smooth aluminum sheath welding method flowchart of the application;

[0025] Figure 2 is a front view schematic diagram of a smooth aluminum sheath welding method matching mechanism of the application;

[0026] Figure 3 is a front view schematic diagram of a smooth aluminum sheath welding method matching mechanism of the application; Figure 2

[0027] Figure 4 is a front view schematic diagram of a smooth aluminum sheath welding method matching mechanism of the application; Figure 2

[0028] Figure 5 is a front view schematic diagram of an aluminum strip flattening mechanism of the application;

[0029] Figure 6 is a right section view schematic diagram of a traction extrusion polishing mechanism of the application.

[0030] Reference signs:

[0031] ​​1, feeding mechanism; 101, first support; 102, bottom plate; 103, aluminum strip feeding roller; 104, motor one; 105, second support; 106, motor two; 107, cable feeding roller; 2, aluminum strip flattening mechanism; 201, C-shaped support; 202, square tube; 203, sliding vertical rod; 204, spring one; 205, extrusion roller; 206, pulley one; 207, pulley two; 208, belt; 209, motor three; 3, wrapping mechanism; 301, wrapping platform; 302, first sleeve; 303, second sleeve; 304, third sleeve; 305, fourth sleeve; 4, double-welding gun mechanism; 401, screw mounting seat; 402, lifting screw; 403, lifting motor; 404, threaded sleeve; 405, cross beam one; 406, mounting frame; 407, distance sensor one; 409, first welding gun; 408, second welding gun; 410, direct current power supply; 411, alternating current 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, sliding seat; 524, drive motor; 525, pulley three; 526, pulley four; 527, spur gear three; 528, gimbal camera; 6, traction extrusion polishing mechanism; 601, limit bolt; 602, base; 603, rectangular frame; 604, L-shaped support; 605, extrusion motor; 606, screw two; 607, stand; 608, cross bar one; 609, rotating seat; 610, first rotating roller; 611, bevel gear one; 612, bevel gear two; 613, transmission shaft; 614, traction motor; 615, sleeve three; 616, polishing motor; 617, sanding disc; 618, sleeve four; 619, vertical frame one; 620, second rotating roller. DETAILED DESCRIPTION

[0032] In order to make the objects, technical solutions and advantages of the present application clearer, the technical solutions in the present application will be described clearly and completely below with reference to the drawings in the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work belong to the scope of protection of the present application.

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

[0034] In addition, the description such as "first", "second" and the like in the present application is only for the purpose of description, and is not intended to particularly indicate the order or sequence, nor to limit the present application, which is merely to distinguish the components or operations described by the same technical terms, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first", "second" can explicitly or implicitly include at least one of the features. In addition, the technical solutions and technical features of various embodiments can be combined with each other, but it must be based on the realization of ordinary skilled in the art, when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, nor within the protection scope required by the present application.

[0035] The present application provides the following embodiments

[0036] Embodiment 1, the present application provides a smooth aluminum sheath welding method, as shown in the figure, comprising: step S1: cleaning the smooth aluminum strip to be welded and the cable end, removing the surface dirt, impurities and the like, to ensure the cleanliness and neatness of the welding surface; Figure 1

[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 tubular shape and wrapped outside the cable;

[0038] Step S3: welding treatment is performed by the double welding gun mechanism 4, and the top gap of the tubular smooth aluminum strip is welded and sealed to form a smooth aluminum sheath by directly welding two aluminum electrodes;

[0039] Step S4: after welding, the cable with the surface smooth aluminum sheath welded is conveyed to the cooling mechanism for weld cooling treatment to room temperature, and the weld is polished and cleaned;

[0040] Step S5: while the welding treatment is being performed, the automatic monitoring system 5 records and monitors the welding arc and the weld, and monitors the cooled weld in real time;

[0041] Step S6: packaging treatment is performed, a layer of heat shrinkable sleeve is first packaged at the weld to ensure that the weld is completely covered, and then a second layer of heat shrinkable sleeve with longer length and uniform sealing around is packaged to enhance the waterproof effect.

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

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

[0044] Preferably, the cooling process in step S4 is a staged cooling process. The first stage of cooling is achieved by blowing air onto the weld surface, and the second stage is achieved by immersing the weld in circulating cooling water in a cooling water tank for cooling. The cooling rate can be controlled by adjusting the circulation rate of the circulating cooling water.

[0045] The beneficial effects of the above technical solution are as follows: The smooth aluminum sheath welding method provided by this invention ensures high-quality welding surfaces through strict cleaning procedures, laying a solid foundation for subsequent welding processes. The design of the feeding mechanism 1 ensures smooth and precise conveying of the smooth aluminum strip and cable end, guaranteeing accurate delivery of welding materials. The adoption of the dual welding gun mechanism 4 not only improves welding efficiency but also significantly enhances welding quality and stability through the coordinated work of the main and backup welding guns and automatic adjustment of welding parameters based on welding progress and real-time quality feedback. The cooling mechanism adopts a staged cooling method, effectively controlling the cooling rate of the weld and avoiding stress and deformation caused by rapid cooling, further ensuring welding quality. The introduction of the automatic monitoring system 5 enables real-time monitoring and recording of the entire welding process, improving production safety and traceability. Finally, the double-layer heat-shrink tubing encapsulation enhances the waterproof effect of the weld and extends the cable's service life. In summary, the method of this invention has advantages such as high efficiency, stability, reliability, and safety, significantly improving the quality and efficiency of smooth aluminum sheath welding.

[0046] Example 2, based on Example 1, such 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 double welding gun mechanism 4, and an automatic monitoring system 5. The feeding mechanism 1 is fixedly installed on the top right side of the base plate 102, the wrapping mechanism 3 is fixedly installed on the left output end of the feeding mechanism, the double welding gun mechanism 4 is fixedly installed on the top of the wrapping mechanism 3, and the automatic monitoring system 5 is fixedly installed on the double welding gun mechanism 4.

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

[0048] The aluminum strip flattening mechanism 2 comprises: a C-shaped support 201 fixedly installed on the left side of the second support 105, a square tube 202 fixedly installed in the middle of the C-shaped support 201 in the left-right direction, a pair of sliding vertical rods 203 symmetrically and slidably connected to the C-shaped support 201, a spring 204 sleeved on the sliding vertical rod 203, an extrusion roller 205 rotationally connected to the end of the sliding vertical rod 203 close to the square tube 202, a belt pulley 206 fixedly connected to the front end of the extrusion roller 205, a belt pulley 207 connected to the belt pulley 206 through a belt 208, and a motor 209 fixedly connected to the output shaft end of the belt pulley 207.

[0049] The wrapping mechanism 3 in step S2 comprises: a wrapping platform 301 fixedly installed on the top end of the middle of the bottom plate 102 in the left-right direction, a first sleeve 302, a second sleeve 303, a third sleeve 304 and a fourth sleeve 305 sequentially installed on the top end of the wrapping platform 301 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 gradually decrease.

[0050] The working principle and beneficial effects of the above technical solution are as follows: when the feeding mechanism 1 operates, the motor 104 drives the aluminum strip feeding roller 103 to rotate to deliver the aluminum strip to the aluminum strip flattening mechanism 2; when the aluminum strip flattening mechanism 2 works, the upper and lower springs 204 symmetrically and elastically press the upper and lower extrusion rollers 205 to the center of the aluminum strip; at the same time, the upper motor 209 rotates clockwise and the lower motor 209 rotates counterclockwise, so that the upper and lower belt pulleys 206 relatively rotate, the belt pulley 206 drives the belt pulley 207 and the extrusion roller 205 to synchronously and relatively rotate through the belt 208, and the upper and lower extrusion rollers 205 relatively rotate to deliver the aluminum strip to the left to pass through the square tube 202 and enter the wrapping mechanism 3; the motor 106 starts to drive the cable feeding roller 107 on the top of the second support 105 to rotate to deliver the cable to the wrapping mechanism 3; the wrapping mechanism 3 gradually reduces the diameters of 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] The embodiment further refines the structure design of the welding device based on embodiment 1. The feeding mechanism 1 is driven by double supports and a motor, realizing smooth and reliable synchronous feeding of the smooth aluminum strip and the cable end. The aluminum strip flattening mechanism 2 effectively guarantees 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 smooth aluminum strip around the cable through gradually reducing sleeves, ensuring the tightness and uniformity of the wrapping. These design improvements not only improve the overall performance of the welding device, but also further enhance 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, reducing the need for manual intervention and improving production efficiency and stability.

[0052] In embodiment 3, based on embodiment 1, as shown in Figures 2-4 The double-welding-gun mechanism 4 in step S3 includes a vertical lead screw mounting seat 401 fixedly installed at the top of the middle part of the base plate 102, a vertical lifting lead screw 402 rotationally connected in the lead screw mounting seat, a lifting motor 403 fixedly connected with the output shaft end of the lifting lead screw 402 at the top end, a threaded sleeve 404 threadedly connected with the lifting lead screw 402, a cross beam one 405 fixedly connected with the front end of the threaded sleeve 404, a pair of mounting brackets 406 symmetrically installed on the left and right of the cross beam one 405, a distance sensor one 407 fixedly installed at the bottom end of the mounting bracket 406 on the right, a first welding gun 409 fixedly installed on the mounting bracket 406 on the left, a second welding gun 408 fixedly installed on the mounting bracket 406 on the left, the first welding gun 409 electrically connected with a direct current power supply 410, and the second welding gun 408 electrically connected with an alternating current power supply 411.

[0053] The automatic monitoring system 5 in step S5 includes a first monitoring mechanism 510 and a second monitoring mechanism 520. The cross beam is fixedly provided with two groups of symmetric first monitoring mechanisms 510 on the left and right. The first monitoring mechanism 510 on the left includes a spur gear one 511 rotationally connected with the left front end of the cross beam one 405, a spur gear two 512 meshingly connected with the spur gear one 511, a servo motor 513 fixedly connected with the output shaft of the spur gear two 512, a first camera 514 fixedly installed at the bottom of the spur gear one 511, and a photosensitive sensor 515 fixedly provided outside the first camera 514. The second monitoring mechanism 520 includes a slide rail 521 fixedly installed in the middle left end of the lead screw mounting seat 401 in the left-right direction, a straight rack 522 fixedly connected with the top end of the slide rail 521 in the left-right direction, a sliding seat 523 slidably connected with the slide rail 521, a gimbal camera 528 fixedly installed at the bottom of the sliding seat 523, and a driving mechanism one providing power for the left-right sliding of the sliding seat 523.

[0054] The driving mechanism comprises: a driving motor 524 fixedly installed on the top of the sliding seat 523, an output shaft of the driving motor 524 is fixedly connected with a belt pulley three 525, the belt pulley three 525 is connected with a belt pulley four 526 through a belt 208, the belt pulley four 526 is rotationally connected with the sliding seat 523, the rear end of the belt pulley four 526 is fixedly connected with a spur gear three 527, and the spur gear three 527 is meshingly connected with the straight rack 522.

[0055] The working principle and beneficial effects of the technical scheme are as follows: when the double-welding-gun mechanism 4 works, the lifting motor 403 drives the lifting lead screw 402 to rotate, the lifting lead screw 402 rotates to drive the threaded sleeve 404 and the beam one 405 to synchronously slide downwards, the distance sensor one 407 is responsible for detecting the distance between the first welding gun 409 and the second welding gun 408 and the welding smooth aluminum, and real-time adjustment is facilitated; meanwhile, the automatic monitoring system 5 firstly operates the first monitoring mechanism 510, the servo motor 513 drives the spur gear one 511 to rotate, the spur gear one 511 drives the spur gear two 512 and the first camera 514 or the second camera to adjust the angle and face the welding direction, the welding arc is monitored in real time, the first camera 514 or the second camera is provided with a dark filter on the surface, the photosensitive sensor 515 provides the angle direction of the welding arc, the first camera 514 or the second camera uploads the image information to the cloud, the operator accesses the cloud to obtain the monitoring information, and the pan-tilt camera 528 of the second monitoring mechanism 520 is responsible for left-right sliding to monitor the appearance of the welded seam after welding; when the sliding seat 523 needs to slide, the driving motor 524 drives the belt pulley three 525 to rotate, the belt pulley three 525 drives the belt pulley four 526 and the spur gear three 527 to synchronously rotate through the belt 208, the spur gear three 527 rotates on the straight rack 522 to drive the sliding seat 523 to slide left and right on the slide rail 521, and the welded seam is reciprocally detected to check whether there is a missed welding or a broken welding position.

[0056] The embodiment focuses on optimizing the design of the double-welding gun mechanism 4 and the automatic monitoring system 5 based on Embodiment 1. The double-welding gun mechanism 4 achieves height and position adjustment of the welding gun through precise cooperation of components such as the lifting lead screw 402, threaded sleeve 404, and cross beam 405, thereby enabling precise control according to welding requirements. At the same time, the coordinated work of the main and backup welding guns, as well as the function of automatically adjusting welding parameters according to the welding process and real-time quality feedback, further enhances welding quality and stability. The automatic monitoring system 5 achieves comprehensive real-time monitoring and recording of the welding process through dual monitoring of the first monitoring mechanism 510 and the second monitoring mechanism 520. The first monitoring mechanism 510 can clearly capture the details of the welding process through the cooperation of the camera and the photosensitive sensor 515; the second monitoring mechanism 520 achieves flexible monitoring of the welding area through the linkage of components such as the slide rail 521, slide base 523, and pulley. 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] In Embodiment 4, based on Embodiment 1, as shown in Figure 2 、 Figure 6 a traction extrusion polishing mechanism 6 is also provided, which includes a base 602 fixedly installed on the left top of the bottom plate 102, a rectangular frame 603 fixedly connected to the top of the base 602, and extrusion mechanisms fixedly provided on the front and rear side walls and the top wall of the rectangular frame 603. The extrusion mechanisms on the front and rear sides are symmetrically arranged along the center of the rectangular frame 603. The extrusion mechanism on the front side includes an L-shaped bracket 604 fixedly connected to the left side wall of the rectangular frame 603, an extrusion motor 605 fixedly installed at the front end of the L-shaped bracket 604, a front-to-back direction lead screw two 606 rotationally connected to the L-shaped bracket 604 and the rectangular frame 603, the front end of the lead screw two 606 fixedly connected to the output shaft of the extrusion motor 605, a vertical stand 607 fixedly connected to the top end of the lead screw two 606, a horizontal bar one 608 fixedly connected to the rear top of the vertical stand 607, and a rotary seat 609 fixedly connected to the rear end of the horizontal bar one 608.

[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 first bevel gear 611, which meshes with the second bevel gear 612. The front end of the second bevel gear 612 is fixedly connected to the drive shaft 613. The drive shaft 613 and the first crossbar 608 slide left and right through the front sidewall of the rectangular frame 603 respectively. The right end of the drive shaft 613 is fixedly connected to the traction motor 614, which is fixedly connected to the upright frame 607. The right end of the rotating seat 609 of the top extrusion mechanism is fixedly installed with the sleeve 615. The top of the sleeve 615 is fixedly installed with the vertical grinding motor 616. The output shaft of the grinding motor 616 is fixedly connected to the grinding disc 617. The bottom of the rectangular frame 603 is fixedly connected to the sleeve 618. The first vertical frame 619 is slidably connected up and down inside the sleeve 618. The top of the first vertical frame 619 is rotatably connected to the second rotating roller 620. The first vertical frame 619 is fixed in the sleeve 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 and grinding mechanism 6 is working, after the smooth aluminum cable is welded, the smooth aluminum and the cable are tightly extruded and bonded together by the traction extrusion and grinding mechanism 6. At the same time, the cable is pulled to the next process. First, the extrusion motor 605 runs, driving the second lead screw 606 to rotate. The rotation of the second lead screw 606 drives the upright 607, the first crossbar 608, the rotating seat 609 and the first rotating roller 610 to slide and move closer to the center until the front, 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, driving 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 pulling it to the left for transport. At the same time, the top grinding motor 616 runs, driving the grinding disc to grind and polish the weld seam at the top of the cable, making the weld seam smoother.

[0060] This embodiment, based on Embodiment 1, adds a traction, compression, and grinding mechanism 6 to further improve the post-weld processing effect. This mechanism, through the precise coordination of components such as the traction motor 614, the compression motor 605, the lead screw 606, and the bevel gear, achieves traction, compression, and grinding of the welded cable. The coordinated work of the traction motor 614 and the compression 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 achieves precise compression and positioning of the cable. The introduction of the grinding motor 616, through the grinding disc 617, grinds the weld seam, removing burrs and uneven parts generated during the welding process, further improving the smoothness and aesthetics of the weld seam. These design improvements not only improve the efficiency and quality of post-weld processing 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, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for welding a smooth aluminum sheath, 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 cable end are conveyed to the wrapping mechanism (3) by the feeding mechanism (1) for processing. The smooth aluminum strip is rolled into a tube and wrapped around the cable. The feeding mechanism includes: a first bracket (101), the first bracket (101) is fixedly installed on the right end of the base plate (102), the top of the first bracket (101) is rotatably connected to an aluminum strip feeding roller (103) in the front and rear directions, the front end of the shaft of the aluminum strip feeding roller (103) is connected to the output shaft of motor one (104), the second bracket (105) is fixedly installed on the left side of the base 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 and rear directions, and the front end of the shaft of the cable feeding roller (107) is connected to motor two (106); Step S3: Welding is performed by a double welding gun mechanism (4), using two types of aluminum welding rods to directly weld the top gap of the tubular smooth aluminum strip to form a smooth aluminum sheath; The dual welding gun mechanism (4) includes: a vertical screw mounting seat (401) fixedly installed at the top of the middle part of the base plate (102), a vertical lifting screw (402) rotatably connected inside the screw mounting seat, the top of the lifting screw (402) being fixedly connected to the output shaft end of the lifting motor (403), the lifting screw (402) being threadedly connected to a threaded sleeve (404), the front end of the threaded sleeve (404) being fixedly connected to a crossbeam (405), a pair of mounting brackets (406) being symmetrically installed on the left and right sides of the crossbeam (405), a distance sensor (407) being fixedly installed at the bottom of the mounting bracket (406), a first welding gun (409) being fixedly installed on the right mounting bracket (406), a second welding gun (408) being fixedly installed on the left mounting bracket (406), the first welding gun (409) being electrically connected to a DC power supply (410), and the second welding gun (408) being electrically connected to an AC power supply (411); Step S4: After welding is completed, the cable with smooth aluminum sheath is transported to the cooling mechanism for cooling the weld to room temperature. At the same time, the weld is ground and cleaned by the traction extrusion grinding mechanism (6). The traction extrusion grinding mechanism (6) includes: a base (602), the base (602) is fixedly installed on the top left side of the base plate (102), a rectangular frame (603) is fixedly connected to the top of the base (602), and extrusion mechanisms are fixedly provided on the front and rear side walls and the top wall of the rectangular frame (603). The extrusion mechanisms on the front and rear sides are symmetrical about the center of the rectangular frame (603). The extrusion mechanism on the front side includes: an L-shaped bracket (604) is fixedly connected to the left side wall of the rectangular frame (603), and the front end of the L-shaped bracket (604) is fixedly installed with... An extrusion motor (605) is mounted on an L-shaped bracket (604), and a second lead screw (606) is rotatably connected between the middle of the L-shaped bracket (604) and the rectangular frame (603). The front end of the second lead screw (606) is fixedly connected to the output shaft of the extrusion motor (605), and the top end of the second lead screw (606) is fixedly connected to a vertical frame (607). The top rear side of the vertical frame (607) is fixedly connected to a first crossbar (608), and the rear end of the first crossbar (608) is fixedly connected to a rotating seat (609). 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 one (611), which meshes with a bevel gear two (612). The front end of the bevel gear two (612) is fixedly connected to a drive shaft (613). The drive shaft (613) and the crossbar one (608) slide left and right through the front sidewall of the rectangular frame (603). The right end of the drive shaft (613) is fixedly connected to a traction motor (614), which is fixedly connected to the upright frame (607). The rotating seat (609) of the top extrusion mechanism The right end is fixedly installed with sleeve three (615), the top of sleeve three (615) is fixedly installed with a vertical grinding motor (616), the output shaft of the grinding motor (616) is fixedly connected to the grinding disc (617), the bottom of the rectangular frame (603) is fixedly connected with sleeve four (618), the sleeve four (618) is slidably connected with vertical frame one (619), the top of vertical frame one (619) is rotatably connected with second rotating roller (620), and vertical frame one (619) is fixed in sleeve four (618) by limiting bolt (601); Step S5: At the same time, during the welding process, the automatic monitoring system (5) records and monitors the welding arc and weld conditions, and monitors the weld after cooling in real time. The automatic monitoring system (5) includes: a first monitoring mechanism (510) and a second monitoring mechanism (520). Two sets of symmetrical first monitoring mechanisms (510) are fixedly installed on the crossbeam. The first monitoring mechanism (510) on the left includes a spur gear (511). The front end of the left side of the crossbeam (405) is rotatably connected to the spur gear (511). The spur gear (511) meshes with the spur gear (512). The spur gear (512) is fixedly connected to the output shaft of the servo motor (513). The bottom of the spur gear (511) is fixedly installed with the first spur gear (511). A camera (514) is provided with a photosensitive sensor (515) fixedly mounted on its exterior; the second monitoring mechanism (520) includes a slide rail (521), the left and right slide rail (521) is fixedly mounted on the middle left end of the lead screw mounting base (401), the top of the slide rail (521) is fixedly connected to the linear rack (522) in the left and right direction, the slide rail (521) is slidably connected to the slide block (523), the bottom of the slide block (523) is fixedly mounted with a gimbal camera (528), and the slide block (523) is powered by a drive mechanism to slide left and right; Step S6: Perform sealing treatment. First, seal the weld seam with a layer of heat shrink tubing to ensure that the weld seam is completely covered. Then, seal a second layer of heat shrink tubing that is longer and evenly sealed on all four sides to enhance the waterproof effect.

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

3. The method for welding a smooth aluminum sheath according to claim 1, characterized in that, In step S4, the cooling process is carried out in stages. The first stage of cooling is to cool the weld surface by blowing air. The second stage is to cool the weld by immersing it in circulating cooling water in a cooling water tank. The cooling rate can be controlled by adjusting the circulation rate of the circulating cooling water.

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

5. The method for welding a smooth aluminum sheath according to claim 1, characterized in that, The packaging mechanism (3) in step S2 includes a packaging platform (301). The packaging platform (301) in the left-right direction is fixedly installed at the top of the middle part of the base plate (102). The top of the packaging platform (301) is installed with a first sleeve (302), a second sleeve (303), a third sleeve (304) and a fourth sleeve (305) from right to left. The diameters of the first sleeve (302), the second sleeve (303), the third sleeve (304) and the fourth sleeve (305) gradually decrease.

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