Automatic welding workstation for aluminum alloy guide pipe

Abstract

The system comprises a safety protection system, the safety protection system comprises a safety fence, an electrical cabinet, a digital welding machine, a robot control cabinet, a welding robot, a two-axis positioner and a tool clamp are installed in the safety fence, a visual monitor is arranged on the safety fence, and a control cabinet and a monitoring displayer are arranged outside the safety fence. An industrial personal computer is installed in the control cabinet, an operation displayer is arranged on the industrial personal computer, and a code scanning gun is installed on the control cabinet. A PLC is installed in the electrical cabinet, an expert process library is loaded in the PLC, a pipeline used for conveying protective gas is connected to the digital welding machine, a tool clamp is arranged on the two-shaft positioner, a magnetic attraction clamp used for clamping an aluminum alloy guide pipe is arranged at one end of the tool clamp, and a connector ring used for clamping a pipe connector is arranged at the other end of the tool clamp. The welding process technological parameters of each aluminum alloy guide pipe can be solidified, it is ensured that the welding parameters in the welding process are consistent, and the one-time welding qualification rate is effectively increased.

Description

Technical Field

[0001] The invention relates to the technical field of aviation welding processing, in particular to an automatic welding workstation for an aluminum alloy conduit. Background Art

[0002] Aluminum alloy conduits are the core links of aircraft. They have a wide variety of pipe diameters, thin wall thickness, and diverse structural forms. They play a vital role in the normal operation of aircraft systems. Traditional aluminum alloy conduit welding uses manual tungsten inert gas arc welding. The aluminum alloy conduits are welded and positioned according to customized tooling, and then workers manually perform circumferential welding. The welded aluminum alloy conduits are subject to visual inspection and X-ray inspection. They are qualified parts if they meet the corresponding weld grade standards. Since aluminum alloy conduits are thin-walled aluminum alloy parts, welding is difficult and requires high welding quality. The manual welding currently used is affected by the workers' technical level and working status, and there are problems such as low production efficiency, low one-time welding pass rate, and unstable welding quality. Summary of the invention

[0003] The technical problem solved by the present invention is to provide an automatic welding workstation for aluminum alloy conduits to solve the problems in the above-mentioned background technology.

[0004] The technical problem solved by the present invention is achieved by adopting the following technical solutions: The aluminum alloy conduit automatic welding workstation includes a control cabinet, a barcode scanner, a monitoring display, an electrical cabinet, a digital welding machine, a robot control cabinet, a welding robot, a two-axis positioner, a fixture, a visual monitor, a safety fence, an operation display and a safety protection system. The safety protection system includes a safety fence, in which an electrical cabinet, a digital welding machine, a robot control cabinet, a welding robot, a two-axis positioner and a fixture are installed. A visual monitor is installed on the safety fence, and a control cabinet and a monitoring display are installed outside the safety fence. An industrial computer is installed in the control cabinet, and an industrial control The machine is equipped with an operation display and a barcode scanner is installed on the control cabinet; a PLC controller is installed in the electrical cabinet, and the PLC controller is loaded with an expert process library for storing aluminum alloy conduit welding parameters; the digital welding machine is connected to a pipeline for delivering protective gas, and the two-axis positioner is equipped with a tooling fixture; the robot control cabinet is respectively connected to the digital welding machine, welding robot, two-axis positioner, and PLC controller, the tooling fixture and safety protection system are connected to the PLC controller, and the monitoring display, visual monitor, operation display, and PLC controller are respectively connected to the industrial computer.

[0005] In the present invention, an alarm light is arranged on the electrical cabinet, and the alarm light is connected to the PLC controller.

[0006] In the present invention, a reset button is provided on the electrical cabinet, and the reset button is connected to the PLC controller.

[0007] In the present invention, a robot controller is arranged in the robot control cabinet, and the digital welding machine, the welding robot, the two-axis positioner and the PLC controller are respectively connected to the robot controller.

[0008] In the present invention, the welding robot includes a welding gun, an arc voltage controller slide, a wire feeder, a wire reel and a six-axis robot, wherein a wire feeder and a wire reel are arranged on one side of the six-axis robot, an arc voltage controller slide for installing an arc voltage controller is arranged on the six-axis robot, the welding gun is arranged at the front end of the arc voltage controller slide, and the arc voltage controller, the welding gun and the wire feeder are respectively connected to the digital welding machine.

[0009] In the present invention, a recording output instrument is arranged on the industrial computer to record the execution working status of each welding task, so as to ensure that the data of the execution process of the aluminum alloy conduit welding task can be traced.

[0010] In the present invention, a magnetic clamp for clamping the aluminum alloy conduit is provided at one end of the tooling fixture, and the clamping position of the aluminum alloy conduit can be flexibly changed by magnetic attraction to adapt to the clamping positioning of aluminum alloy conduits with different directions. A joint ring for clamping the pipe joint is provided at the other end of the tooling fixture. The joint ring is pneumatically controlled, and the pipe joint and the aluminum alloy conduit are fixed by an internal support design. The joint ring is installed on the pneumatic slip ring provided on the tail frame of the two-axis positioner to ensure that when the two-axis positioner drives the tooling fixture to rotate, the pneumatic slip ring drives the aluminum alloy conduit and the pipe joint to rotate synchronously, thereby ensuring smooth implementation of welding.

[0011] In the present invention, the magnetic clamp is provided with replaceable clamps of different sizes to adapt to the clamping of aluminum alloy conduits of different diameters and the welding of other parts.

[0012] The aluminum alloy conduit automatic welding workstation performs the following steps for automatic welding of aluminum alloy conduits in real time: First, the PLC controller is system tested. When everything is normal, the QR code set on the aluminum alloy conduit to be welded is scanned by a barcode scanner to identify the model of the aluminum alloy conduit to be welded. Then, the PLC controller calls the welding parameters corresponding to the aluminum alloy conduit of this model and downloads them to the industrial computer. The aluminum alloy conduit to be welded is manually clamped and positioned on the fixture. The PLC controller controls the welding robot to move the aluminum alloy conduit to be welded to the welding position, and controls the digital welder and the two-axis positioner to weld according to the welding parameters. During the welding process, the industrial computer monitors the welding parameters in real time, and monitors the welding voltage of the digital welder through the arc voltage controller and adjusts the height of the welding gun in real time to ensure the stability of the welding voltage during the welding process. After the welding is completed, the welding robot and the two-axis positioner return to the initial position, and the worker disassembles the welded aluminum alloy conduit, thereby completing the welding of an aluminum alloy conduit. During the above automatic welding process, the visual monitor monitors the welding operation area of ​​the welding workstation in real time and displays it on the monitor display; The barcode scanner communicates with the industrial computer arranged in the control cabinet through the USB interface, scans the QR code set on the aluminum alloy conduit to be welded, so as to identify the model of the aluminum alloy conduit to be welded, and calls the corresponding welding parameters of the aluminum alloy conduit in the expert process library built into the industrial computer through the aluminum alloy conduit model, including the welding robot program number, the number of segments, the angle of each segment, the welding speed, the welding current, the wire feeding speed, etc. The PLC controller is arranged in the electrical cabinet to efficiently manage and transmit data to the welding workstation, monitor the operation status of the welding workstation in real time, and ensure the stable and reliable operation of the welding workstation; The robot controller controls the welding robot and the two-axis positioner to perform linkage control on the welding robot and the two-axis positioner to realize path planning of complex weld paths. The robot controller is embedded with the control program required by the workstation. The robot controller is connected to the PLC controller through the ProfitNet bus, and the associated control variables realize the PLC controller to control the welding robot program. The digital welding machine controls the wire feeder and welding gun, and communicates with the robot controller through the DeviceNet bus to realize the welding implementation parameter requirements of the welding robot at different weld positions; The arc voltage controller is connected to the digital welding machine and welding gun through hard wiring. The arc voltage controller control circuit monitors the real-time voltage between the welding gun and the workpiece during welding. The arc voltage is kept stable by adjusting the distance between the welding gun and the workpiece by adjusting the arc voltage controller slide table. The safety protection system isolates the welding workstation from the outside world through a safety fence, and sets a safety grating and a safety door lock on the safety fence to protect the welding in a safe working state.

[0013] In the present invention, an HMI controller is also provided on the PLC controller. The HMI controller is a standby controller used to replace the operation display to implement the sending and control of welding parameters of the aluminum alloy conduit welding task.

[0014] Beneficial effects: The present invention can improve the welding process of aluminum alloy conduits, reduce the influence of human factors on the welding quality of aluminum alloy conduits during welding, solidify the welding process parameters of each aluminum alloy conduit, ensure the consistency of welding parameters during the welding process, and effectively improve the one-time welding pass rate; at the same time, the tooling fixture is highly flexible and can be used as a welding test platform for other parts, effectively shortening the test cycle and providing technical support for product replacement or replacement. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a top view of a preferred embodiment of the present invention.

[0016] Figure 2 It is a side view of a preferred embodiment of the present invention.

[0017] Figure 3 It is a schematic diagram of the principle of a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0018] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below with reference to specific diagrams.

[0019] See also Figures 1 to 3 The aluminum alloy conduit automatic welding workstation includes a control cabinet 1, a barcode scanner 2, a monitoring display 3, an electrical cabinet 4, a digital welding machine 5, a protective gas 6, a robot control cabinet 7, a welding robot 8, a two-axis positioner 9, a fixture 10, a visual monitor 11, a safety fence 12, an operation display 13 and a safety protection system, wherein the safety protection system includes a safety fence 12, in which the electrical cabinet 4, the digital welding machine 5, the robot control cabinet 7, the welding robot 8, the two-axis positioner 9 and the fixture 10 are installed, the safety fence 12 is provided with a visual monitor 11, the safety fence 12 is provided with a control cabinet 1 and a monitoring display 3 outside the safety fence 12, and the control cabinet 1 is provided with a control cabinet 1. An industrial computer is installed, a PLC controller is installed in the electrical cabinet 4, an operation display 13 is arranged on the industrial computer, an expert process library is loaded in the PLC controller, a barcode scanner 2 is installed on the control cabinet 1, a pipeline for conveying protective gas 6 is connected to the digital welding machine 5, the digital welding machine 5, the welding robot 8, and the two-axis positioner 9 are respectively connected to the robot control cabinet 7, the robot control cabinet 7 and the safety protection system are connected to the PLC controller, a tooling fixture 10 is arranged on the two-axis positioner 9, the tooling fixture 10 is connected to the PLC controller, the PLC controller, the monitoring display 3, the robot control cabinet 7, the visual monitor 11, and the operation display 13 are respectively connected to the industrial computer.

[0020] In this embodiment, an alarm light is provided on the electrical cabinet 4, and the alarm light is connected to the PLC controller.

[0021] In this embodiment, a reset button is provided on the electrical cabinet 4, and the reset button is connected to the PLC controller.

[0022] In this embodiment, a robot controller is disposed in the robot control cabinet 7, and the digital welding machine 5, the welding robot 8, and the two-axis positioner 9 are respectively connected to the robot controller.

[0023] In this embodiment, the welding robot 8 includes a welding gun 81, an arc voltage controller slide 82, a wire feeder 83, a wire reel 84 and a six-axis robot 85, wherein a wire feeder 83 and a wire reel 84 are arranged on one side of the six-axis robot 85, an arc voltage controller slide 82 for installing an arc voltage controller is arranged on the six-axis robot 85, the welding gun 81 is arranged at the front end of the arc voltage controller slide 82, and the arc voltage controller, the welding gun 81 and the wire feeder 83 are respectively connected to the digital welding machine 5.

[0024] In this embodiment, the two-axis positioner 9 includes a two-axis positioner first axis 91 , a two-axis positioner tail frame 92 and a two-axis positioner second axis 93 .

[0025] The aluminum alloy conduit automatic welding workstation performs the following steps for automatic welding of aluminum alloy conduits in real time: First, the PLC controller is system-checked. After the PLC controller is normal, the QR code set on the aluminum alloy conduit to be welded is scanned by the barcode scanner 2 to identify the model of the aluminum alloy conduit to be welded, and then the PLC controller calls the welding parameters corresponding to the aluminum alloy conduit of this model and downloads them to the industrial computer. The aluminum alloy conduit to be welded is manually clamped and positioned on the fixture 10. The PLC controller controls the welding robot 8 to move to the welding position, and controls the digital welder 5 and the two-axis positioner 9 to weld according to the welding parameters of the PLC controller. During the welding process, the industrial computer monitors the welding parameters in real time, and monitors the welding voltage of the digital welder 5 through the arc voltage controller and adjusts the height of the welding gun 81 in real time to ensure that the welding voltage is stable during the welding process. After the welding is completed, the welding robot 8 and the two-axis positioner 9 return to the initial position, and the worker disassembles the welded aluminum alloy conduit, thereby completing the welding of an aluminum alloy conduit; During the above automatic welding process, the visual monitor 11 monitors the welding operation area of ​​the welding workstation in real time and displays it on the monitor display 3. The industrial computer is provided with a recording output instrument to record the execution status of each welding task, so as to ensure that the data of the aluminum alloy conduit welding task execution process can be traced; The barcode scanner 2 communicates with the industrial computer arranged in the control cabinet 1 through the USB interface, scans the QR code set on the aluminum alloy conduit to be welded, so as to identify the model of the aluminum alloy conduit to be welded, and calls the corresponding welding parameters of the aluminum alloy conduit in the expert process library built into the PLC controller according to the aluminum alloy conduit model, including the welding robot 8 program number, the number of segments, the angle of each segment, the welding speed, the welding current, the wire feeding speed, etc.; The operation display 13 is the display interface of the industrial computer. The display interface program is developed based on C# software to realize functions such as authority management, task management, process library management, real-time data display, historical data management and alarm management. Operators with different operation permissions enter different operation interfaces and send tasks to the PLC controller to send welding parameters to control the automatic welding workstation. The PLC controller is arranged in the electrical cabinet 4, and performs efficient management and data transmission of the welding workstation, monitors the operation status of the welding workstation in real time, and ensures the stable and reliable operation of the welding workstation. When an alarm is encountered or the emergency stop is pressed, the alarm light on the electrical cabinet 4 emits an audible and visual alarm. After checking the cause of the alarm and handling the alarm, click the reset button on the electrical cabinet 4 to restore the welding workstation to a normal state; The robot controller controls the welding robot 8 and the two-axis positioner 9 to perform linkage control on the welding robot 8 and the two-axis positioner 9 to realize path planning of complex weld paths. The robot controller is embedded with the control program required by the workstation, and is connected to the PLC controller through the ProfitNet bus. The associated control variables realize the program control of the welding robot 8 by the PLC controller. The digital welding machine 5 controls the wire feeder 83 and the welding gun 81, and communicates with the robot controller via the DeviceNet bus to realize the welding implementation parameter requirements of the welding robot 8 at different weld positions; The arc voltage controller is connected to the digital welding machine 5 and the welding gun 81 through hard wiring. The arc voltage controller control circuit monitors the real-time voltage between the welding gun 81 and the workpiece during welding, and the arc voltage is kept stable by adjusting the distance between the welding gun 81 and the workpiece by adjusting the arc voltage controller slide 82 to lift and lower; The fixture 10 is designed according to the diameter, shape and pipe joint form of the compatible aluminum alloy conduit. A magnetic clamp is provided at one end of the fixture 10 for clamping the aluminum alloy conduit. The clamping position of the aluminum alloy conduit can be flexibly changed by magnetic attraction to adapt to the clamping and positioning of aluminum alloy conduits with different directions. A joint ring is provided at the other end of the fixture 10 for clamping the pipe joint. The joint ring is pneumatically controlled and the power is compressed air. The pipe joint and the aluminum alloy conduit are fixed by an internal support design. The joint ring is installed on the pneumatic slip ring provided on the tail frame 92 of the two-axis positioner to ensure that when the two-axis positioner 9 drives the fixture 10 to rotate, the pneumatic slip ring drives the aluminum alloy conduit and the pipe joint to rotate synchronously, thereby ensuring smooth implementation of welding. The magnetic clamp is provided with a chuck, which can be replaced with chucks of different sizes to adapt to the welding of aluminum alloy conduits and other parts with different pipe diameters; The safety protection system isolates the welding workstation from the outside world through a safety fence 12, and sets a safety grating and a safety door lock on the safety fence 12 to protect the welding in a safe working state; Workers are only allowed to process aluminum alloy conduits according to the matching process parameters and cannot modify the process parameters; process technicians have the authority to modify the process parameters.

[0026] The PLC controller is also provided with an HMI controller, which is a standby controller used to replace the operation display 13 to implement the sending and control of welding parameters for the aluminum alloy conduit welding task.

Claims

1. Aluminum alloy conduit automatic welding workstation, including control cabinet, barcode scanner, monitoring display, electrical cabinet, digital welding machine, robot control cabinet, welding robot, two-axis positioner, fixture, visual monitor, safety fence, operation display and safety protection system, characterized in that: The safety protection system includes a safety fence, in which an electrical cabinet, a digital welding machine, a robot control cabinet, a welding robot, a two-axis positioner and a tooling fixture are installed, a visual monitor is arranged on the safety fence, a control cabinet and a monitoring display are arranged outside the safety fence, an industrial computer is installed in the control cabinet, an operation display is arranged on the industrial computer, and a barcode scanner is installed on the control cabinet; a PLC controller is installed in the electrical cabinet, and the PLC controller is loaded with an expert process library for storing aluminum alloy conduit welding parameters, the digital welding machine is connected to a pipeline for conveying protective gas, a tooling fixture is arranged on the two-axis positioner, and a magnetic clamp for clamping the aluminum alloy conduit is arranged at one end of the tooling fixture, and a joint ring for clamping the pipe joint is arranged at the other end of the tooling fixture; the robot control cabinet is connected to the digital welding machine, the welding robot, the two-axis positioner and the PLC controller respectively, the tooling fixture and the safety protection system are connected to the PLC controller, and the monitoring display, the visual monitor, the operation display and the PLC controller are connected to the industrial computer respectively.

2. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: The welding robot includes a welding gun, an arc voltage controller slide, a wire feeder, a welding wire reel and a six-axis robot, wherein a wire feeder and a welding wire reel are arranged on one side of the six-axis robot, an arc voltage controller slide for installing an arc voltage controller is arranged on the six-axis robot, the welding gun is arranged at the front end of the arc voltage controller slide, and the arc voltage controller, the welding gun and the wire feeder are respectively connected to the digital welding machine.

3. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: An alarm light is provided on the electrical cabinet and is connected to the PLC controller.

4. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: A reset button is provided on the electrical cabinet, and the reset button is connected to the PLC controller.

5. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: A robot controller is arranged in the robot control cabinet, and a digital welding machine, a welding robot, a two-axis positioner and a PLC controller are respectively connected to the robot controller.

6. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: The industrial computer is provided with a recording output instrument.

7. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: The joint ring is installed on the pneumatic slip ring arranged on the tail frame of the two-axis positioner.

8. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: The magnetic clamp is provided with replaceable clamps of different sizes.

9. The aluminum alloy conduit automatic welding workstation according to claim 1 is characterized in that: The PLC controller is also equipped with an HMI controller.

10. The aluminum alloy conduit automatic welding workstation according to any one of claims 1 to 9 is used to perform automatic welding of the aluminum alloy conduit in real time, characterized in that: Here are the steps: First, the PLC controller is system tested. When everything is normal, the QR code set on the aluminum alloy conduit to be welded is scanned by a barcode scanner to identify the model of the aluminum alloy conduit to be welded. Then the PLC controller calls the welding parameters corresponding to the model of the aluminum alloy conduit and downloads them to the industrial computer. The aluminum alloy conduit to be welded is manually clamped and positioned on the fixture. The PLC controller controls the welding robot to move the aluminum alloy conduit to be welded to the welding position, and controls the digital welder and the two-axis positioner to weld according to the welding parameters. During the welding process, the industrial computer monitors the welding parameters in real time, monitors the welding voltage of the digital welder through the arc voltage controller, and adjusts the height of the welding gun in real time to ensure the stability of the welding voltage during the welding process. After the welding is completed, the welding robot and the two-axis positioner return to their initial positions, and the workers disassemble the welded aluminum alloy conduit, thereby completing the welding of an aluminum alloy conduit.

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