Automatic welding equipment for thin film enclosure system

Abstract

The invention relates to the field of welding, in particular to automatic welding equipment for a film enclosure system, which comprises a base, a supporting column is fixedly connected to the top surface of the base, a guide rail is mounted on the supporting column, a moving box is slidably connected to the guide rail, and a connecting block is vertically slidably connected to one side of the moving box. A welding gun connecting box is fixedly connected to the side, away from the moving box, of the connecting block, a welding gun is rotationally connected to the side, away from the connecting block, of the welding gun connecting box, a translation component enabling the moving box to move is arranged in the moving box, and an angle adjusting component driving the welding gun to rotate is arranged in the welding gun connecting box. A height detection component is installed on the side, away from the connecting block, of the welding gun connecting box. The welding efficiency of the thin film enclosure system can be improved, and the welding quality is ensured.

Description

Technical Field

[0001] The invention relates to the field of welding, and in particular to an automatic welding device for a film enclosure system. Background Art

[0002] The membrane enclosure system is widely used in the fields of liquefied natural gas (LNG) storage tanks, and its core components include stainless steel corrugated plates and high-nickel steel membranes. The welding quality of these components directly affects the sealing and safety of the system. The plates used in the membrane enclosure system often have uneven surfaces, and the traditional manual welding process has problems such as low efficiency and unstable quality. Therefore, the development of an automated welding equipment has important practical significance. Summary of the invention

[0003] The object of the present invention is to provide an automated welding device for a film enclosure system to solve the above-mentioned problem, so as to improve the welding efficiency of the film enclosure system and ensure the welding quality.

[0004] To achieve the above object, the present invention provides the following solutions: An automated welding device for a film enclosure system comprises a base, a support column fixedly connected to the top surface of the base, a guide rail installed on the support column, a movable box slidably connected to the guide rail, a connecting block vertically slidably connected to one side of the movable box, a welding gun connecting box fixedly connected to the side of the connecting block away from the movable box, a welding gun rotatably connected to the side of the welding gun connecting box away from the connecting block, a translation component for moving the movable box is provided in the movable box, an angle adjustment component for driving the welding gun to rotate is provided in the welding gun connecting box, and a height detection component is installed on the side of the welding gun connecting box away from the connecting block.

[0005] Preferably, the translation component includes a first motor fixedly connected to the moving box, the first motor shaft is connected to a gear, a rack is fixedly connected to the middle of the top surface of the guide rail, and the gear is meshed with the rack.

[0006] Preferably, the angle adjustment component includes a third motor, the output shaft of the third motor is connected to a worm, the worm is meshed with a worm wheel, the worm wheel shaft is connected to a rotating shaft, the rotating shaft is rotatably connected to the side wall of the welding gun connecting box and extends out of the welding gun connecting box, and the end of the rotating shaft away from the worm wheel is fixedly connected to the welding gun.

[0007] Preferably, the height detection component includes a sleeve fixedly connected to the side of the welding gun connection box, a movable rod movably connected inside the sleeve, a ball rotatably connected to the bottom end of the movable rod, a height measuring piece is provided between the movable rod and the sleeve, and a first spring is installed between the top end of the movable rod and the sleeve.

[0008] Preferably, the height measuring component comprises a resistance bar embedded in the inner wall of the sleeve, a slider is laterally slidably connected to the side wall of the movable rod, a second spring is provided between the slider and the movable rod, and the slider is in contact with the resistance bar.

[0009] Preferably, a lifting component for moving the connecting block up and down is installed in the moving box.

[0010] Preferably, the lifting component includes a second motor installed in the moving box, the second motor shaft is connected to a screw, the screw cooperates with the connecting block, a guide rod is installed in the moving box, the connecting block is slidably matched with the guide rod, and the guide rod and the screw are vertically arranged.

[0011] Preferably, the connecting block is a telescopic motor.

[0012] Preferably, a side wall of the moving box is provided with a clearance groove, and the connecting block is movably arranged in the clearance groove.

[0013] The present invention has the following technical effects: During welding, the plate to be welded is placed on the base through the support frame, the equipment is started, and the translation component drives the moving box to move, which in turn drives the welding gun connection box and the welding gun to move. During the movement of the welding gun, the height detection component can detect the raised and recessed parts on the plate. The angle adjustment component can make the welding gun adapt to welding in different shape areas of the plate, so that the angle of the welding gun is adapted to the plate, thereby improving the welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0015] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the internal structure of the mobile box of the present invention; Figure 3 This is a schematic diagram of the internal structure of the welding gun connection box of the present invention; Figure 4 This is a schematic diagram of the matching structure of the sleeve and the movable rod of the present invention; Figure 5 It is a structural diagram of embodiment 2 of the present invention.

[0016] Among them, 1. base; 2. support column; 3. guide rail; 301. rack; 4. moving box; 401. gear; 402. drive shaft; 403. first motor; 404. screw; 405. second motor; 406. guide rod; 407. make way groove; 5. connecting block; 6. welding gun connecting box; 601. third motor; 602. worm; 7. welding gun; 701. rotating shaft; 702. worm gear; 8. sleeve; 801. movable rod; 802. rolling ball; 803. first spring; 804. second spring; 805. slider; 806. resistor bar; 10. telescopic support rod; 1001. ball head. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0019] Example 1

[0020] Reference Figure 1-Figure 4 As shown, this embodiment provides an automated welding equipment for a film enclosure system, including a base 1, a support column 2 is fixedly connected to the top surface of the base 1, a guide rail 3 is installed on the support column 2, a mobile box 4 is slidably connected to the guide rail 3, a connecting block 5 is vertically slidably connected to one side of the mobile box 4, a welding gun connecting box 6 is fixedly connected to the side of the connecting block 5 away from the mobile box 4, a welding gun 7 is rotatably connected to the side of the welding gun connecting box 6 away from the connecting block 5, a translation component for moving the mobile box 4 is provided in the mobile box 4, an angle adjustment component for driving the welding gun 7 to rotate is provided in the welding gun connecting box 6, and a height detection component is installed on the side of the welding gun connecting box 6 away from the connecting block 5.

[0021] During welding, the plate to be welded is placed on the base 1 through the support frame, the equipment is started, and the translation component drives the moving box 4 to move, which in turn drives the welding gun connecting box 6 and the welding gun 7 to move. During the movement of the welding gun 7, the height detection component can detect the raised and recessed parts on the plate, and the angle adjustment component can make the welding gun 7 adapt to the welding in different shape areas of the plate, so that the angle of the welding gun 7 is adapted to the plate, thereby improving the welding quality.

[0022] According to a further optimized solution, the translation component includes a first motor 403 fixedly connected in the moving box 4, the shaft of the first motor 403 is connected with a gear 401, a rack 301 is fixedly connected to the middle of the top surface of the guide rail 3, and the gear 401 is meshed with the rack 301.

[0023] By controlling the first motor 403 to rotate, the first motor 403 drives the gear 401 to rotate. Since the gear 401 is meshed with the rack 301, the moving box 4 can be driven to move to a suitable position on the guide rail 3 by controlling the forward and reverse rotation of the first motor 403.

[0024] A further optimized solution is that the angle adjustment component includes a third motor 601, the output shaft of the third motor 601 is connected to a worm 602, the worm 602 is meshed with a worm wheel 702, the worm wheel 702 is connected to a rotating shaft 701, the rotating shaft 701 is rotatably connected to the side wall of the welding gun connecting box 6 and extends out of the welding gun connecting box 6, and the end of the rotating shaft 701 away from the worm wheel 702 is fixedly connected to the welding gun 7.

[0025] By controlling the third motor 601 to rotate, the third motor 601 drives the worm 602 to rotate and the worm wheel 702 to rotate, and then the welding gun 7 can achieve a suitable angle adjustment to adapt to the plate to be welded. After such adjustment, the worm 602 can lock the worm wheel 702, thereby improving the stability of the welding gun 7.

[0026] A further optimized solution is that the height detection component includes a sleeve 8 fixedly connected to the side of the welding gun connection box 6, a movable rod 801 is movably connected inside the sleeve 8, a ball 802 is rotatably connected to the bottom end of the movable rod 801, a height measuring part is provided between the movable rod 801 and the sleeve 8, and a first spring 803 is installed between the top of the movable rod 801 and the sleeve 8.

[0027] During welding, the ball 802 contacts the surface of the plate to be welded. When the ball 802 passes over the surface of the plate, the ball 802 will rise and fall with the surface of the plate. The movable rod 801 can transmit the rise and fall to the height measuring part, thereby providing an input reference for adjusting the angle of the welding gun 7.

[0028] A further optimized solution is that the height measuring component includes a resistance bar 806 embedded in the inner wall of the sleeve 8, a slider 805 is laterally slidably connected to the side wall of the movable rod 801, a second spring 804 is provided between the slider 805 and the movable rod 801, and the slider 805 is in contact with the resistance bar 806.

[0029] By connecting electrodes on the resistor bar 806 and the slider 805, when the ball 802 moves up and down, the contact position between the slider 805 and the resistor bar 806 changes, thereby realizing the detection of unevenness on the surface of the plate.

[0030] To further optimize the solution, a lifting component is installed in the moving box 4 to move the connecting block 5 up and down.

[0031] A further optimized solution is that the lifting component includes a second motor 405 installed in the moving box 4, the shaft of the second motor 405 is connected to a lead screw 404, the lead screw 404 cooperates with the connecting block 5, a guide rod 406 is installed in the moving box 4, the connecting block 5 and the guide rod 406 are slidably matched, and the guide rod 406 and the lead screw 404 are vertically arranged.

[0032] By controlling the second motor 405 to rotate, the second motor 405 drives the lead screw 404 to rotate, and the lead screw 404 can drive the connecting block 5 to move up and down, thereby driving the welding gun connecting box 6 and the welding gun 7 to move, thereby realizing the adjustment of the height of the welding gun 7. In combination with the detection of the height measuring part, the welding gun 7 can be placed in a suitable position relative to the welding plate for welding, thereby ensuring the welding quality.

[0033] According to a further optimized solution, the connecting block 5 is a telescopic motor.

[0034] According to a further optimized solution, a clearance groove 407 is provided on the side wall of the moving box 4 , and the connecting block 5 is movably arranged in the clearance groove 407 .

[0035] When in use, the plate to be welded is placed on the base 1 through the support frame, and the first motor 403 is controlled to rotate, and the first motor 403 drives the gear 401 to rotate. Since the gear 401 and the rack 301 are meshed, the first motor 403 is controlled to rotate forward and reverse, so that the moving box 4 can be driven to move on the guide rail 3, and then the welding gun connecting box 6 and the welding gun 7 are driven to move. During the movement of the welding gun 7, the ball 802 contacts the surface of the plate to be welded. When the ball 802 passes over the surface of the plate, the ball 802 will rise and fall with the surface of the plate. The ups and downs can be transmitted to the height measuring part through the movable rod 801, and the raised and recessed parts on the plate can be detected, thereby providing an input reference for the angle adjustment of the welding gun 7. By controlling the third motor 601 to rotate, the third motor 601 drives the worm 602 to rotate and the worm wheel 702 to rotate, and then the welding gun 7 can achieve a suitable angle adjustment to adapt to the plate to be welded. After such adjustment, the worm 602 can lock the worm wheel 702, which improves the stability of the welding gun 7.

[0036] Example 2

[0037] Reference Figure 5 As shown, the only difference between this embodiment and the first embodiment is that a plurality of telescopic support rods 10 are fixedly connected to one side of the top surface of the base 1 , the plurality of telescopic support rods 10 are arranged in an array, and a ball head 1001 is fixedly connected to the top surface of the telescopic support rod 10 .

[0038] With this arrangement, by adjusting the elongated shape of the telescopic support rods 10, on the one hand, it can adapt to the uneven shape of the surface of the plate to be welded, and on the other hand, it can also adapt to the shape of the plate according to the actual target welding shape, thereby ensuring better support stability of the plate to be welded when placed on the base 1, further improving the stability of welding.

[0039] High-precision welding is established through a machine self-learning model. The height detection components include a laser weld tracking sensor and a contact position sensor. The laser weld tracking sensor is installed at the front end of the welding gun 7 in the direction of travel. The contact position sensor is installed between the laser weld tracking sensor and the welding gun 7. The welding gun 7 is also provided with a reflective optical fiber sensor. The laser weld tracking sensor is installed at the front side of the welding gun in the direction of travel. It scans the weld area at a frequency of 1000Hz to generate high-precision three-dimensional point cloud data, and detects the weld position, plate surface undulation and joint geometric features in real time. The contact position sensor uses a high-precision probe mechanism to perform physical contact measurement at key positions such as the welding starting point, end point and path corners to verify the accuracy of the laser weld tracking sensor data. The system sets a difference threshold of 0.1mm. The reflective optical fiber sensor monitors the distance change between the welding gun and the workpiece surface in real time, with a measurement accuracy of 0.005mm. Set up the LSTM time series prediction model: adopt a two-layer LSTM network structure, input the continuous time series point cloud data collected by the laser sensor, and output the ideal position coordinates of the welding gun at the next 5 time points. The network contains two layers of LSTM units with 64 and 32 neurons, and uses the relu activation function and dropout layer to prevent overfitting, and specifically learns the periodic characteristics and thermal deformation laws of the surface corrugation of the plate; Set up a 3D CNN feature extraction model: convert the laser point cloud data into a 32×32×32 voxel grid, extract spatial features through a 3D convolution layer (32 3×3×3 convolution kernels) and a maximum pooling layer, identify different types of weld joints (such as flat butt joints, corner joints, corrugated plate lap joints, etc.), and provide geometric feature input for subsequent control decisions; DDPG reinforcement learning model: Contains Actor-Critic dual network structure. The Actor network uses a fully connected layer of 256-128 nodes, inputs the current welding state (sensor data + process parameters), and outputs the adjustment of welding gun speed, angle and height; the Critic network evaluates the action value and continuously optimizes the strategy through time difference learning. The custom reward function comprehensively considers the weld penetration, surface forming and defect probability; Control strategy: The Kalman filter algorithm is used to fuse multi-sensor data. The weight of laser sensor data is set to 0.8, and the weight of contact sensor data is set to 0.2. When environmental interference (such as welding spatter) causes abnormal laser data, it automatically switches to the contact sensor dominant mode.

[0040] Establish a priority control mechanism: the distance data of the reflective fiber optic sensor directly controls the lifting motor (response time <1ms), the trajectory prediction results of the LSTM control the translation motor, and the optimization instructions of the DDPG model control the angle adjustment motor. The three are synchronized in microseconds through the EtherCAT bus; Specific working process: Initialization phase: The laser sensor performs a full-width scan of the area to be welded to generate an initial three-dimensional topographic map. This process is performed by controlling the operation of the first motor 403, which drives the mobile box 4 to move along the guide rail 3, and in this process, the second motor 405 is controlled to operate in combination with the relevant distance detected by the laser sensor, and the second motor 405 drives the lead screw 404 to rotate, and the lead screw 404 drives the connecting block 5 to move up and down to adapt to the different shapes of the plate, and complete the detection of the first weld. After completing one movement, the telescopic motor is controlled to operate, which will move the laser sensor to the next weld, and the first motor 403 is controlled to operate again to drive the mobile box 4 to move, and the second weld is detected. By analogy, a full-width scan of the belt area is achieved.

[0041] The contact sensor calibrates the starting and ending positions of the weld. By controlling the operation of the first motor 403, the second motor 405, and the telescopic motor, the contact sensor is moved to the starting position of the weld. Similarly, the contact sensor can also be moved to the key position of the weld. The starting and ending positions of the weld are calibrated by moving the position of the contact sensor and cooperating with the contact sensor.

[0042] The offline pre-trained model loads initial parameters.

[0043] Welding operation stage: Real-time data collection: The laser sensor continuously collects point cloud data and generates a set of coordinate sequences every 2ms. The movement of the laser sensor is achieved through the coordinated operation of the first motor 403, the second motor 405, and the telescopic motor.

[0044] Trajectory prediction: The LSTM model processes time series data and predicts the ideal path of the welding gun within the next 10ms.

[0045] Parameter optimization: The DDPG model dynamically adjusts the current, speed, and swing amplitude according to the current welding status (including plate temperature estimation).

[0046] Execution control: During the translation process, the first motor 403 drives the gear 401 to move along the guide rail 3 to advance the welding gun 7. During the lifting process, the second motor 405 drives the lead screw 404 to maintain a constant welding arc length. During the angle adjustment process, the third motor 601 drives the worm 602 and the worm wheel 702 to ensure that the welding gun 7 is always perpendicular to the plate surface.

[0047] Online learning phase: After each 1-meter weld is completed, the system automatically analyzes the forming quality of the welding section and can set up visual inspection (such as taking pictures with an industrial camera or providing feedback on subsequent flaw detection data).

[0048] An incremental learning algorithm is used to update the LSTM model parameters, focusing on optimizing the prediction accuracy of special joints (such as the peak / valley of corrugated plates).

[0049] The experience replay buffer of the DDPG model stores 1,000 sets of state-action-reward data, and updates the policy network every 8 hours: Specifically, the data structure and storage mechanism include: Status information: 128-dimensional vector (laser point cloud features, welding parameters, equipment status); Action output: 3D vector (speed adjustment, angle adjustment, height adjustment); Reward value: comprehensive score based on welding quality (floating point number); EndFlag: Boolean (marks the end of a welding segment); The buffer capacity is set to 1,000 records, which can cover the complete process data of a typical weld of 20-30 meters; Intelligent sampling strategy: Based on the priority sampling mechanism, the sampling probability formula is:

[0050] Among them, δ_i represents the temporal difference error (TD-error). 64 records are randomly selected for each batch of training, taking into account the training efficiency and video memory limitation. Buffer initialization requires pre-storing 200 basic data to ensure training stability; Policy update trigger and execution mechanism: Update trigger conditions: Time trigger: The equipment has been running for 8 hours (about 400-600 meters of welds completed); Abnormal trigger: the proportion of new data exceeds 30%; the welding quality score drops by more than 5% recently; Safety trigger: Detection of Q value fluctuations exceeding 15% for three consecutive batches.

[0051] Update execution process: (1) Data preprocessing stage, automatically clean up old data that is more than 14 days old, Intelligent segmentation of continuous welding tracks (minimum unit ≥ 10 continuous states); (2) Network parameter update: Critic Network Update:

[0052] The target value

[0053] Actor network updates use policy gradients:

[0054] Target network synchronization, using soft update method (τ=0.001):

[0055] Industrial-grade optimized design: Compound Reward Function:

[0056] The quality term is converted using an S-curve:

[0057] The efficiency term is linearly normalized:

[0058] Cosine constraint of energy consumption term:

[0059] After setting up the DDPG model, the welding quality control improved the penetration fluctuation coefficient from 8.2% to 5.7%; the porosity incidence was reduced by 1.7 percentage points; production efficiency was optimized; the frequency of manual intervention was reduced from 9 times per shift to 3 times, the shielding gas consumption was reduced by 12.5%, the system stability was shown, the strategy update process took <3 minutes (background thread execution), and the maximum memory occupancy was small.

[0060] In the description of the present invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0061] The embodiments described above are only descriptions of the preferred modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. An automated welding device for a membrane enclosure system, characterized in that: The invention comprises a base (1), wherein a support column (2) is fixedly connected to the top surface of the base (1), a guide rail (3) is installed on the support column (2), a movable box (4) is slidably connected to the guide rail (3), a connecting block (5) is vertically slidably connected to one side of the movable box (4), a welding gun connecting box (6) is fixedly connected to the side of the connecting block (5) away from the movable box (4), a welding gun connecting box (6) is rotatably connected to the side of the welding gun connecting box (6) away from the connecting block (5), a translation component for moving the movable box (4) is provided in the movable box (4), an angle adjustment component for driving the welding gun (7) to rotate is provided in the welding gun connecting box (6), and a height detection component is installed on the side of the welding gun connecting box (6) away from the connecting block (5); The height detection component comprises a sleeve (8) fixedly connected to the side of the welding gun connection box (6), a movable rod (801) movably connected inside the sleeve (8), a rolling ball (802) rotatably connected to the bottom end of the movable rod (801), a height measuring member is provided between the movable rod (801) and the sleeve (8), and a first spring (803) is installed between the top end of the movable rod (801) and the sleeve (8); The height measuring component comprises a resistance bar (806) embedded in the inner wall of the sleeve (8), a slider (805) is laterally slidably connected in the side wall of the movable rod (801), a second spring (804) is provided between the slider (805) and the movable rod (801), and the slider (805) is in contact with the resistance bar (806).

2. The automatic welding equipment for a film enclosure system according to claim 1, characterized in that: The translation component comprises a first motor (403) fixedly connected in the moving box (4), the shaft of the first motor (403) being connected to a gear (401), a rack (301) being fixedly connected in the middle of the top surface of the guide rail (3), and the gear (401) being meshed with the rack (301).

3. The automated welding equipment for a membrane enclosure system according to claim 1, characterized in that: The angle adjustment component comprises a third motor (601), the output shaft of the third motor (601) is connected to a worm (602), the worm (602) is meshed with a worm wheel (702), the worm wheel (702) is connected to a rotating shaft (701), the rotating shaft (701) is rotatably connected to a side wall of the welding gun connection box (6) and extends out of the welding gun connection box (6), and one end of the rotating shaft (701) away from the worm wheel (702) is fixedly connected to the welding gun (7).

4. The automatic welding equipment for a membrane enclosure system according to claim 1, characterized in that: A lifting component for moving the connecting block (5) up and down is installed in the moving box (4).

5. The automatic welding equipment for a membrane enclosure system according to claim 4, characterized in that: The lifting component comprises a second motor (405) installed in the moving box (4); the shaft of the second motor (405) is connected to a lead screw (404); the lead screw (404) cooperates with the connecting block (5); a guide rod (406) is installed in the moving box (4); the connecting block (5) and the guide rod (406) are slidably matched; the guide rod (406) and the lead screw (404) are vertically arranged.

6. The automated welding equipment for a membrane enclosure system according to claim 1, characterized in that: The connecting block (5) is a telescopic motor.

7. The automated welding equipment for a membrane enclosure system according to claim 5, characterized in that: The side wall of the movable box (4) is provided with a clearance groove (407), and the connecting block (5) is movably arranged in the clearance groove (407).

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