An automated welding robot capable of recognizing welding trajectories

Abstract

This invention discloses an automated welding robot capable of recognizing welding trajectories, comprising a base, a machine platform, and a welding robot. The machine platform is mounted on the base, and the welding robot is mounted on top of the machine platform. The welding robot includes a large arm, a forearm, and a welding mechanism. A driver connects the large arm and the forearm, and the welding mechanism is mounted at the front end of the forearm. This invention is equipped with a welding trajectory recognition system. This not only improves welding accuracy but also reduces human error and increases production efficiency. The welding mechanism includes a grinding mechanism, comprising a motor, a probe, and a grinding cylinder, which can effectively perform pre-weld seam grinding and post-weld surface treatment, improving the smoothness and appearance quality of the weld joint. This grinding mechanism allows the robot to not only perform welding but also to perform a certain degree of post-processing, reducing the need for manual grinding. During the grinding process, the grinding mechanism can also pre-recognize the welding trajectory, improving welding accuracy.

Description

Technical Field

[0001] This invention relates to the field of welding robot technology, specifically to an automated welding robot capable of recognizing welding trajectories. Background Technology

[0002] Welding robots, as the name suggests, are robots responsible for welding work and belong to the category of industrial robots. Industrial robots typically include a freely rotating robotic arm with multiple programmable axes. Welding robots, on the other hand, are industrial robots with a welding torch as their end effector. To ensure that the robot can track the weld seam trajectory, an arc sensor needs to be installed on the robot. By detecting the height and lateral deviation of the welding torch, the sensor provides input signals to the automatic weld seam tracking system of gas-shielded welding, thereby enabling the welding robot to automatically track the weld seam. When welding tube sheets or complex workpieces with intersecting lines and high welding difficulty, in addition to the conventional robotic arm used for welding, welding robots also need to be equipped with a positioner for fixing the workpiece.

[0003] Existing welding robots often rely on preset programs or externally manually input trajectories when performing complex welding tasks. This may result in insufficient accuracy of trajectory recognition, especially on complex welding paths and high-difficulty workpieces. The deviation between the welding trajectory and the predetermined trajectory is large, which may lead to inconsistent welding quality. Furthermore, pre-processing of the welding area is required before welding, resulting in poor welding efficiency. Therefore, an automatic welding robot that can recognize welding trajectories is proposed. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this invention provides an automated welding robot capable of recognizing welding trajectories. This solves the problems of existing welding robots relying on preset programs or manually input trajectories when performing complex welding tasks. This can lead to insufficient accuracy in trajectory recognition, especially on complex welding paths and high-difficulty workpieces, where the deviation between the welding trajectory and the predetermined trajectory is large, potentially resulting in inconsistent welding quality. Furthermore, pre-processing of the weld area is required before welding, leading to poor welding efficiency.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: an automatic welding robot capable of recognizing welding trajectories, comprising a base, a machine platform, and a welding robot, wherein the machine platform is mounted on the base, the welding robot is mounted on the top of the machine platform, and the welding robot includes a large arm, a small arm, and a welding mechanism, wherein a driver is connected between the large arm and the small arm, and the welding mechanism is mounted on the front end of the small arm;

[0008] The welding mechanism includes an adjustment box, a T-shaped frame, a welding torch, and a grinding mechanism. Fixed seats are provided on both sides of the top of the T-shaped frame. The welding torch is mounted on one of the fixed seats, and the grinding mechanism is mounted on the other fixed seat. The grinding mechanism includes a probe and a motor. The motor is mounted on the back of the fixed seat, and its power output end is connected to the end of the probe. A grinding cylinder is mounted on the surface of the probe. A vertical pipe is vertically mounted at the lower end of the T-shaped frame, and an adjustment plate is mounted at the lower end of the vertical pipe. The adjustment plate is connected to the adjustment box. The rear end of the adjustment box is fixedly connected to the front end of the forearm. A dust removal fan is installed inside the adjustment box.

[0009] A control box is installed on one side of the top surface of the base, and the control box contains a welding trajectory recognition system and a welding robot control system.

[0010] As a further preferred embodiment of the present invention, a guide column is vertically installed on one side of the top of the regulating box. The lower end of the guide column extends into the regulating box and is connected to the port of the dust removal fan. A telescopic hose is installed on the upper side wall of the guide column. A guide ring is fixedly installed at the end of the telescopic hose. The guide ring is sleeved on the vertical pipe and rotatably connected to the vertical column. A through hole is opened on the surface of the vertical pipe and the through hole is located inside the guide ring.

[0011] As a further preferred embodiment of the present invention, an air guide box is installed on the top surface of the T-shaped frame and between the two fixed seats. The side wall of the air guide box has an insertion hole and a dust collection box is embedded inside the insertion hole. The front end of the air guide box is connected to the side wall of the fixed seat. The air guide box has an air guide hole inside and the air guide hole communicates with the inside of the riser.

[0012] As a further preferred embodiment of the present invention, air inlets are provided on both sides and the front end of the fixing base, and the air inlets are all connected to the air guide box.

[0013] As a further preferred embodiment of the present invention, an air inlet is provided at one end of the dust collection box, a filter screen is provided at the other end of the dust collection box, and a handle is installed in the middle of the outer wall of the dust collection box.

[0014] As a further preferred embodiment of the present invention, two sets of closed diaphragms are symmetrically arranged inside the air inlet. The closed diaphragms are made of rubber material and have magnetic plates installed at their ends. The two symmetrically arranged closed diaphragms are connected by magnetic plates.

[0015] As a further preferred embodiment of the present invention, the welding trajectory recognition system includes a welding power source, a sensing component, a signal acquisition card, a filter, an amplifier circuit, and a digital-to-analog conversion circuit.

[0016] (III) Beneficial Effects

[0017] This invention provides an automated welding robot capable of recognizing welding trajectories. It offers the following advantages:

[0018] This invention is equipped with a welding trajectory recognition system, which can monitor the accuracy of the welding path in real time and ensure the stability of welding quality during the welding process. This not only improves welding accuracy but also reduces human error and increases production efficiency. The welding mechanism is equipped with a grinding mechanism, including a motor, probe, and grinding cylinder, which can effectively perform pre-weld grinding and surface treatment of the weld seam and post-weld grinding, improving the smoothness and appearance quality of the weld joint. This grinding mechanism enables the robot not only to perform welding but also to perform a certain degree of post-processing, reducing the need for manual grinding. The grinding mechanism can also pre-identify the welding trajectory during the grinding process, improving welding accuracy. Attached Figure Description

[0019] Figure 1 This is a structural diagram of the automatic welding robot capable of recognizing welding trajectories described in this invention;

[0020] Figure 2 This is an external structural diagram of the welding mechanism described in this invention;

[0021] Figure 3 This is a diagram of the internal structure of the T-shaped frame described in this invention;

[0022] Figure 4 for Figure 3 Enlarged view of A in the middle;

[0023] Figure 5 This is a flowchart of the automatic welding robot capable of recognizing welding trajectories described in this invention.

[0024] In the diagram: 1. Base; 2. Machine platform; 3. Control box; 4. Boom; 5. Driver; 6. Arm; 7. Welding mechanism; 8. Probe; 9. Grinding cylinder; 10. Mounting base; 11. Air inlet; 12. Motor; 13. Dust collection box; 14. Riser; 15. Air guide box; 16. T-shaped frame; 17. Welding torch; 18. Adjustment box; 19. Air guide column; 20. Telescopic hose; 21. Air guide ring; 22. Adjustment disc; 23. Filter screen; 24. Air guide hole; 25. Air inlet; 26. Closed diaphragm. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Please see Figure 1-5 The present invention provides a technical solution: an automatic welding robot capable of recognizing welding trajectories, comprising a base 1, a machine platform 2, and a welding robot. The machine platform 2 is mounted on the base 1, and the welding robot is mounted on the top of the machine platform 2. The welding robot includes a large arm 4, a small arm 6, and a welding mechanism 7. A driver 5 is connected between the large arm 4 and the small arm 6. The welding mechanism 7 is mounted on the front end of the small arm 6. This is the basic composition of the welding robot.

[0027] The welding mechanism 7 includes an adjustment box 18, a T-shaped frame 16, a welding torch 17, and a grinding mechanism. Fixed seats 10 are respectively provided on both sides of the top of the T-shaped frame 16. The welding torch 17 is mounted on one of the fixed seats 10, and the grinding mechanism is mounted on the other fixed seat 10. The grinding mechanism includes a probe 8 and a motor 12. The motor 12 drives the probe 8 to rotate. The motor 12 is mounted on the back of the fixed seat 10, and its power output end is connected to the end of the probe 8. A grinding cylinder 9 is installed on the surface of the probe 8. The grinding cylinder 9 grinds the welding seam and can also clean the welding slag after welding. A vertical pipe 14 is installed vertically at the lower end of the T-shaped frame 16. An adjustment plate 22 is installed at the lower end of the vertical pipe 14. The adjustment plate 22 is connected to the adjustment box 18. The rear end of the adjustment box 18 is fixedly connected to the front end of the forearm 6. A dust removal fan is installed inside the adjustment box 18, providing dust removal power.

[0028] A control box 3 is installed on one side of the top surface of the base 1. The control box 3 contains a welding trajectory recognition system and a welding robot control system.

[0029] Further improvements include a vertically mounted air guide column 19 on one side of the top of the regulating box 18, with the lower end of the air guide column 19 extending into the regulating box 18 and connecting to the port of the dust collector fan. A telescopic hose 20 is installed on the upper side wall of the air guide column 19 to meet the rotation requirements of the T-shaped frame 16. An air guide ring 21 is fixedly installed at the end of the telescopic hose 20. The air guide ring 21 is sleeved on the riser 14 and rotatably connected to the riser. A through hole is opened on the surface of the riser 14 and the through hole is located inside the air guide ring 21 to achieve the effect of air guidance.

[0030] In a further improvement, an air guide box 15 is installed on the top surface of the T-shaped frame 16 and between the two fixed seats 10. The side wall of the air guide box 15 has an insertion hole and a dust collection box 13 is embedded inside the insertion hole. The front end of the air guide box 15 is connected to the side wall of the fixed seat 10. The air guide box 15 has an air guide hole 24 inside and the air guide hole 24 is connected to the inside of the riser 14. The dust collection box 13 filters the incoming air and leaves the debris in the dust collection box 13.

[0031] Further improvements include air inlets 11 on both sides and the front end of the mounting base 10, all of which are connected to the air guide box 15. One end of the dust collection box 13 has an air inlet 25, and the other end has a filter screen 23. A handle is installed in the middle of the outer wall of the dust collection box 13 for easy removal and cleaning.

[0032] In a further improvement, two sets of closed diaphragms 26 are symmetrically arranged inside the air inlet 25. The closed diaphragms 26 are made of rubber material and have magnetic plates installed at their ends. The two symmetrically arranged closed diaphragms 26 are connected by magnetic plates. After the dust removal fan is turned off, the two closed diaphragms 26 are connected together.

[0033] Further improvements include a welding trajectory recognition system comprising a welding power source, sensing components, a signal acquisition card, a filter, an amplifier circuit, and a digital-to-analog converter circuit.

[0034] The steps of arc tracking:

[0035] Step 1: Acquire the electrical signal of the welding arc

[0036] Signal acquisition: Arc voltage and current signals are acquired in real time through the welding power source (DC welding machine or AC welding machine) and sensing components (voltage sensor, current sensor, contact sensor, etc.). Arc voltage is closely related to factors such as arc length and arc temperature, while the current signal is related to welding current and heat distribution of the welding arc.

[0037] Signal transmission: The acquired arc voltage and arc current signals are transmitted to the signal processing unit via a data acquisition card.

[0038] Step 2: Process the acquired electrical signals

[0039] Signal filtering: Arc signals may be affected by noise interference, so the acquired signals need to be filtered. Common filtering methods include low-pass filters, high-pass filters, or band-pass filters, which are used to remove high-frequency noise or low-frequency drift.

[0040] Signal amplification: If the signal is weak, it can be amplified by an amplifier circuit to ensure that the signal can be accurately analyzed in subsequent processing stages.

[0041] Analog-to-digital converter (ADC): Converts analog arc voltage and current signals into digital signals, facilitating subsequent digital signal processing and analysis. The accuracy of the ADC is crucial to the overall system accuracy.

[0042] Feature extraction: Using digital signal processing methods, such as Fourier transform, time-domain analysis, and wavelet transform, feature parameters (such as voltage fluctuation amplitude, current waveform, and spectrum analysis) related to weld position and welding quality are extracted from the arc signal.

[0043] Step 3: Calculate the deviation of the weld.

[0044] Feature parameter analysis: The extracted feature parameters are used to analyze the trend of arc variation and identify the deviation between the arc and the weld center. For example, the fluctuation range of arc voltage may reflect the degree of arc offset.

[0045] Algorithm Application: Neural network algorithms, fuzzy logic algorithms, and least squares methods are used to calculate the deviation between the electric arc and the weld. Neural networks can learn from historical data and extract nonlinear features; fuzzy logic can handle the fuzziness and uncertainty of the arc signal.

[0046] Deviation calculation: Based on the extracted feature parameters and welding process requirements, the deviation of the weld (such as transverse deviation, longitudinal deviation, etc.) is calculated and judged to determine whether correction is needed.

[0047] Step 4: Feedback on deviation and adjust the welding robot's motion trajectory

[0048] Deviation feedback: The calculated deviation is fed back to the welding robot's control system. The control system can be a computer numerical control (CNC) based control system or a real-time feedback system based on an industrial robot control platform.

[0049] Motion trajectory adjustment: The control system uses PID control algorithms, fuzzy control algorithms, or other optimization algorithms (such as adaptive control, predictive control, etc.) to adjust the motion trajectory of the welding robot in real time based on the deviation. PID control can reduce deviation by continuously adjusting motion parameters (such as speed and acceleration); fuzzy control can handle complex and fuzzy situations, such as small fluctuations in the arc position.

[0050] Real-time weld seam tracking: Based on feedback and adjustment information, the welding robot corrects its motion trajectory in real time to achieve precise tracking of the weld seam. Adjustments to the robot's motion trajectory may include longitudinal or lateral offsets, or even movement of the welding arc, to ensure weld quality.

[0051] Step 5: Real-time monitoring and quality control

[0052] Welding quality inspection: This involves real-time monitoring of weld quality using a combination of arc signals and image processing technology (such as cameras or laser scanning systems). Image processing can detect features such as weld width, depth, and shape, thereby assessing weld quality.

[0053] Real-time feedback mechanism: A feedback mechanism is established to continuously monitor the arc signal, robot movement trajectory, and welding quality during the welding process, ensuring that the welding process remains within the set process parameter range. If a quality problem is detected, the system can adjust the welding parameters in a timely manner to avoid unqualified welds.

[0054] Step Six: Learning and Optimization

[0055] Data Acquisition and Analysis: As the welding process continues, the system can continuously collect welding data (arc voltage, current, robot motion trajectory, weld images, etc.) and use machine learning methods to optimize the arc tracking algorithm. Deep learning or reinforcement learning can help improve the system's adaptability and robustness.

[0056] Process optimization: Through data analysis, identify the impact of different process parameters on welding quality and optimize the welding process.

[0057] Working principle: The workpieces to be welded are clamped and fixed, forming a gap between them. The grinding cylinder 9 is inserted into the gap for grinding. At the same time, the welding trajectory is pre-identified by the probe 8. After identification, the identification information is recorded in the welding trajectory recognition system. The welding torch 17 is driven to weld the workpiece. During the welding process, the electrical signal of the welding arc is collected, processed and compared with the pre-identified signal to calculate the deviation of the weld. The deviation is fed back and the motion trajectory of the welding robot is adjusted. After welding, the weld slag is treated.

[0058] The present invention comprises the following components: 1. base; 2. machine platform; 3. control box; 4. upper arm; 5. driver; 6. forearm; 7. welding mechanism; 8. probe; 9. grinding cylinder; 10. fixed base; 11. air inlet; 12. motor; 13. dust collection box; 14. riser; 15. air guide box; 16. T-shaped frame; 17. welding torch; 18. adjustment box; 19. air guide column; 20. telescopic hose; 21. air guide ring; 22. adjustment disc; 23. filter screen; 24. air guide hole; 25. air inlet; 26. closed diaphragm. All components are general standard parts or parts known to those skilled in the art, and their structure and principle can be understood by those skilled in the art through technical means. As learned from books or conventional experimental methods, the problem solved by this invention is that existing welding robots, when performing complex welding tasks, often rely on preset programs or externally manually input trajectories. This can lead to insufficient accuracy in trajectory recognition, especially on complex welding paths and high-difficulty workpieces, where the deviation between the welding trajectory and the predetermined trajectory is large, potentially resulting in inconsistent welding quality. Furthermore, pre-processing of the weld area is required before welding, leading to poor welding efficiency. This invention, through the combination of the aforementioned components, is equipped with a welding trajectory recognition system that can monitor the accuracy of the welding path in real time and ensure stable welding quality during the welding process. This not only improves welding accuracy but also reduces human error and increases production efficiency. The welding mechanism 7 is equipped with a grinding mechanism, including a motor 12, a probe 8, and a grinding cylinder 9, which can effectively perform pre-weld seam grinding and post-weld surface treatment, improving the smoothness and appearance quality of the weld joint. This grinding mechanism allows the robot to not only perform welding but also to perform a certain degree of post-processing, reducing the need for manual grinding. The grinding mechanism can also pre-recognize the welding trajectory during the grinding process, improving welding accuracy.

[0059] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0060] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An automated welding robot capable of recognizing welding trajectories, comprising a base (1), a machine platform (2), and a welding robot, characterized in that: The machine platform (2) is mounted on the base (1), the welding robot is mounted on the top of the machine platform (2) and the welding robot includes a large arm (4), a small arm (6) and a welding mechanism (7). A driver (5) is connected between the large arm (4) and the small arm (6), and the welding mechanism (7) is mounted on the front end of the small arm (6). The welding mechanism (7) includes an adjustment box (18), a T-shaped frame (16), a welding torch (17), and a grinding mechanism. The top two sides of the T-shaped frame (16) are respectively provided with fixed seats (10). The welding torch (17) is installed on one of the fixed seats (10), and the grinding mechanism is installed on the other fixed seat (10). The grinding mechanism includes a probe (8) and a motor (12). The motor (12) is installed on the back of the fixed seat (10) and its power output end is connected to the end of the probe (8). A grinding cylinder (9) is installed on the surface of the probe (8). A vertical pipe (14) is installed vertically at the lower end of the T-shaped frame (16). An adjustment plate (22) is installed at the lower end of the vertical pipe (14). The adjustment plate (22) is connected to the adjustment box (18). The rear end of the adjustment box (18) is fixedly connected to the front end of the forearm (6). A dust removal fan is installed inside the adjustment box (18). A control box (3) is installed on one side of the top surface of the base (1), and the control box (3) is equipped with a welding trajectory recognition system and a welding robot control system. A guide column (19) is vertically installed on one side of the top of the regulating box (18). The lower end of the guide column (19) extends into the regulating box (18) and is connected to the port of the dust removal fan. A telescopic hose (20) is installed on the upper side wall of the guide column (19). A guide ring (21) is fixedly installed at the end of the telescopic hose (20). The guide ring (21) is sleeved on the riser (14) and rotatably connected to the riser. A through hole is opened on the surface of the riser (14) and the through hole is located inside the guide ring (21). An air guide box (15) is installed on the top surface of the T-shaped frame (16) and between the two fixed seats (10). The side wall of the air guide box (15) has an insertion hole and a dust collection box (13) is embedded inside the insertion hole. The front end of the air guide box (15) is connected to the side wall of the fixed seat (10). An air guide hole (24) is opened inside the air guide box (15) and the air guide hole (24) is connected to the inside of the riser (14).

2. The automatic welding robot capable of recognizing welding trajectories according to claim 1, characterized in that: The fixed base (10) has air inlets (11) on both sides and at the front end, and the air inlets (11) are all connected to the air guide box (15).

3. The automatic welding robot capable of recognizing welding trajectories according to claim 1, characterized in that: The dust collection box (13) has an air inlet (25) at one end and a filter screen (23) at the other end. A handle is installed in the middle of the outer wall of the dust collection box (13).

4. An automatic welding robot capable of recognizing welding trajectories according to claim 3, characterized in that: The air inlet (25) is symmetrically provided with two sets of closed diaphragms (26). The closed diaphragms (26) are made of rubber material and have magnetic plates installed at their ends. The two symmetrically arranged closed diaphragms (26) are connected by magnetic plates.

5. An automatic welding robot capable of recognizing welding trajectories according to claim 1, characterized in that: The welding trajectory recognition system includes a welding power source, sensing components, a signal acquisition card, a filter, an amplifier circuit, and a digital-to-analog conversion circuit.

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