Driving disc assembly combined welding machine and operation method thereof

Abstract

The invention discloses a driving disc assembly combined welding machine and an operation method thereof, and relates to the technical field of welding, the welding machine comprises a welding work station, a to-be-welded station is arranged at the front end of the welding work station, a welding station is arranged in the welding work station, and a rotation unit is arranged in the middle of the to-be-welded station and the middle of the welding station; two workbenches are symmetrically installed on the rotary unit, one workbench is located on a station to be welded, the other workbench is located on a welding station, and clamps are arranged on the workbenches. By adopting the design that the three mechanical arms are symmetrically distributed in the circumferential direction, the three guns work at the same time, the production efficiency is remarkably improved, in addition, each mechanical arm is provided with the TI G welding gun and the MI G (or MAG) welding gun at the same time, rapid switching can be achieved, the switching time of the whole process from preheating to welding to heat preservation is extremely short (completed within 3-5 seconds), and the production efficiency is greatly improved. Heat diffusion loss is effectively reduced, and continuous and stable welding quality is ensured.

Description

Technical Field

[0001] The invention relates to the technical field of welding, in particular to a drive disc assembly combined welding machine and an operating method thereof. Background Art

[0002] In modern industrial manufacturing, welding technology is widely used in the connection of various metal structures. For some metal materials with high carbon equivalent content, such as high carbon steel, alloy steel, etc., cracks and deformation are prone to occur during welding, so preheating and insulation treatment are required. Traditional preheating and insulation methods usually use flame heating or electric heating, but these methods have problems such as uneven heating, low efficiency, complex operation, and are difficult to achieve automatic control. In addition, the prior art lacks a device that can simultaneously perform preheating, insulation and welding during the welding process, and cannot effectively solve the problems of welding deformation and heat loss.

[0003] Based on this, a drive disc assembly combined welding machine and an operation method thereof are now provided, which can eliminate the disadvantages of existing welding machines. Summary of the invention

[0004] The object of the present invention is to provide a drive disc assembly combined welding machine and an operating method thereof to solve the problems in the background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A drive disc assembly combined welding machine comprises a welding workstation, wherein a welding station is arranged at the front end of the welding workstation, a welding station is arranged inside the welding workstation, a rotary unit is arranged in the middle of the welding station and the welding station, two workbenches are symmetrically mounted on the rotary unit, one of the workbenches is located at the welding station, and the other workbenches is located at the welding station, a fixture is arranged on the workbenches, three manipulators are installed in a circular distribution with the welding station as the center inside the welding workstation, one of the manipulators is suspended and installed inside the welding workstation to avoid interfering with the normal operation of the rotary unit, and each of the manipulators is simultaneously mounted with welding gun 1 and welding gun 2.

[0007] Preferably, welding power supply 1 and welding power supply 2 are installed on the upper end of the welding workstation, welding power supply 1 is used to power welding gun 1, and welding power supply 2 is used to power welding gun 2, and a guardrail is fixed around welding power supply 1 and welding power supply 2 on the upper end of the welding workstation.

[0008] Preferably, an ambient temperature sensor is installed at the front end of the welding workstation, and a welding area temperature sensor is installed on the manipulator. The ambient temperature sensor and the welding area temperature sensor are connected to a control system arranged inside a PLC controller. The PLC controller is installed on one side of the front end of the welding workstation. The PLC controller is electrically connected to the manipulator and welding gun 1 and welding gun 2 installed on the manipulator.

[0009] Preferably, a plurality of cameras are arranged inside the welding workstation, a monitoring display is arranged at the front end of the welding workstation, and the cameras are connected to the monitoring display.

[0010] Preferably, the first welding gun is a MIG welding gun or a MAG welding gun, and the second welding gun is a TIG welding gun.

[0011] Preferably, a camera and a barcode scanner are installed at the front end of the welding workstation, the camera is located between the ambient temperature sensor and the barcode scanner, the barcode scanner is used to scan the QR code and bind and store the welding data, and alarm lights are installed on the top of both sides of the welding workstation, and the camera is electrically connected to the alarm lights.

[0012] A method for operating a drive disc assembly combined welding machine comprises the following steps:

[0013] S1: First, load the workpiece onto the workbench located at the welding station, and clamp the workpiece with a fixture. The barcode scanner scans the QR code and binds and stores the welding data. The camera performs workpiece recognition. If the recognition is correct, continue. Otherwise, the alarm light is triggered and the operation is terminated.

[0014] S2: Then, the workbench at the position of the to-be-welded station is rotated to the welding station position by using the rotary unit. At this time, the workbench previously located at the welding station position is rotated to the to-be-welded station position;

[0015] S3: Next, the robot is switched to TIG preheating mode through the PLC controller, and the welding gun 2 discharges and heats the material in the welding area; then the robot is switched to MIG or MAG welding mode, and welding is performed through welding gun 1; after welding is completed, the robot is switched to TIG insulation mode, and welding gun 2 discharges and heats the welding area. During the insulation stage, the temperature sensor in the welding area monitors and feeds back the temperature of the welding area after welding in real time;

[0016] S4: During the welding process, another workbench prepares the next workpiece at the station to be welded and repeats the steps in S1, including workpiece loading, clamping, code scanning and data binding, workpiece identification and error handling;

[0017] S5: After welding is completed, the robot returns to the initial state; the welded workpiece rotates from the welding station to the waiting welding station along with the workbench through the rotary unit, ready for unloading; at this time, the workbench that was previously at the waiting welding station and the workpiece on it rotate to the welding station, starting a new round of welding operation, and the above process is repeated.

[0018] A method for operating a drive disc assembly combined welding machine, wherein the step S3 further comprises:

[0019] S31: presetting key parameters required in the welding process through the PLC controller, including but not limited to the current value and feed speed of the initial TIG preheating mode, the current value and feed speed of the initial TIG insulation mode, the current value and voltage value of the MIG or MAG welding mode, the expected welding area temperature after preheating is completed, the expected temperature of the welding area (i.e., the welding spot) before insulation begins, and the target temperature of the welding area (welding spot) after insulation ends;

[0020] S32: Switch welding gun 2 to TIG preheating mode to preheat the welding area; the welding area temperature sensor collects the preheated welding area temperature in real time and compares the data with the preset temperature. According to the temperature difference, the PLC controller adjusts the preheating current and feed speed of the next cycle: if the measured temperature is lower than the preset value, the preheating current is increased and the feed speed is appropriately reduced to enhance the preheating effect;

[0021] S33: After preheating is completed, switch the welding gun to MIG or MAG welding mode, and perform welding operations according to preset current and voltage parameters;

[0022] S34: When welding is about to end or immediately after it ends, the temperature of the area to be kept warm is measured by the temperature sensor in the welding area, and the measured temperature is compared with the preset temperature before keeping warm. According to the temperature difference, the current or feed speed of the second welding gun is adjusted to prepare for the keeping warm stage. If the measured temperature is higher than the preset value, the current is appropriately reduced or the feed speed is increased; if the measured temperature is lower than the preset value, the temperature difference is converted into the adjustment amount of the current and feed speed in the preheating stage to prepare for the next cycle;

[0023] S35: Switch welding gun 2 to T IG insulation mode to perform discharge insulation treatment on the welding area; after the insulation is completed, use the welding area temperature sensor to measure the temperature of the welding area again, and compare it with the preset post-insulation temperature; according to the temperature difference, the PLC controller adjusts the current and feed speed of welding gun 2 in the next cycle to ensure the continuous stability of welding quality.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention realizes three guns working simultaneously by adopting the design of three manipulators with symmetrical distribution of the circumference, which significantly improves the production efficiency. In addition, each manipulator is equipped with a TIG welding gun and a MIG (or MAG) welding gun at the same time, and can switch quickly. The switching time from preheating to welding and then to insulation is extremely short (completed within 3-5 seconds), which effectively reduces heat diffusion loss and ensures the continuous stability of welding quality.

[0026] 2. The present invention realizes real-time monitoring and precise control of the entire welding process through temperature sensors and PLC controllers; the real-time collected temperature data of the environment and welding area are automatically optimized for TIG preheating and insulation current and duration after system analysis, and precise temperature control. This intelligent strategy greatly improves welding accuracy and stability, while reducing energy consumption; in addition, this technology optimizes the cracks and metallographic structure of the weld area, significantly enhances mechanical properties, and is widely applicable to various types of metal materials that require preheating and insulation, with broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the front end position of the present invention.

[0028] Figure 2 It is a structural schematic diagram of the side end position of the present invention.

[0029] Figure 3 This is a position distribution diagram of the welding station, welding station, rotary unit and manipulator of the present invention.

[0030] Figure 4 It is a schematic structural diagram of the manipulator of the present invention.

[0031] Figure 5 The flowchart of the method of operation of the present invention is shown in FIG.

[0032] Figure 6 Flow chart of step S3 of the present invention.

[0033] Notes on the accompanying drawings: 11. Welding workstation; 12. Station to be welded; 13. Welding station; 14. Rotating unit; 15. Workbench; 16. Fixture; 17. Manipulator; 18. Welding gun one; 19. Welding gun two; 20. Welding area temperature sensor; 21. Ambient temperature sensor; 22. Camera; 23. Barcode scanner; 24. Monitoring display; 25. Camera; 26. Alarm light; 27. Welding power source one; 28. Welding power source two; 29. ​​Guardrail; 30. PLC controller. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0035] In one embodiment, Figure 1-Figure 4 As shown, a drive disc assembly combined welding machine includes a welding workstation 11, a welding station 12 is arranged at the front end of the welding workstation 11, a welding station 13 is arranged inside the welding workstation 11, a rotating unit 14 is arranged in the middle of the welding station 12 and the welding station 13, two workbenches 15 are symmetrically installed on the rotating unit 14, one of the workbenches 15 is located at the welding station 12, and the other workbenches 15 is located at the welding station 13, a fixture 16 is arranged on the workbenches 15, three manipulators 17 are installed in a circular distribution with the welding station 13 as the center inside the welding workstation 11, one of the manipulators 17 is suspended and installed inside the welding workstation 11 to avoid interfering with the normal operation of the rotating unit 14, and each of the manipulators 17 is simultaneously installed with a welding gun 18 and a welding gun 2 19.

[0036] In this embodiment, through the cooperation of the rotating unit 14 and the three manipulators 17, rapid conversion and precise welding of the parts to be welded are achieved, thereby improving production efficiency; the hanging installation design of the manipulator 17 avoids interference with the rotating unit 14, demonstrating the flexibility of equipment design and optimization of space utilization.

[0037] In an optional embodiment, a welding power supply 27 and a welding power supply 28 are installed at the upper end of the welding workstation 11, the welding power supply 27 is used to power the welding gun 18, and the welding power supply 28 is used to power the welding gun 2 19, and a guardrail 29 is fixed around the welding power supply 27 and the welding power supply 28 at the upper end of the welding workstation 11.

[0038] It should be noted that welding power supply 1 27 and welding power supply 2 28 provide stable and adequate power supply to welding gun 1 18 and welding gun 2 19 respectively, thereby improving the accuracy and reliability of welding; the main function of guardrail 29 is to prevent personnel from accidentally contacting the power supply area, thereby avoiding potential risks of electric shock.

[0039] In an optional embodiment, an ambient temperature sensor 21 is installed at the front end of the welding workstation 11, and a welding area temperature sensor 20 is installed on the manipulator 17. The ambient temperature sensor 21 and the welding area temperature sensor 20 are connected to a control system arranged inside a PLC controller 30. The PLC controller 30 is installed on one side of the front end of the welding workstation 11. The PLC controller 30 is electrically connected to the manipulator 17 and welding gun 1 18 and welding gun 2 19 installed on the manipulator 17.

[0040] It should be noted that by integrating temperature sensors (ambient temperature sensor 21, welding area temperature sensor 20) and PLC controller, real-time monitoring and precise control of the welding process are achieved, which helps to improve the accuracy, stability and efficiency of welding.

[0041] In an optional embodiment, a plurality of cameras 25 are disposed inside the welding workstation 11 , a monitoring display 24 is disposed at the front end of the welding workstation 11 , and the cameras 25 are connected to the monitoring display 24 .

[0042] It should be noted that, through the cooperation between the camera 25 and the monitoring display 24 , the welding status of the workpiece inside the welding workstation 11 can be observed on the monitoring display 24 .

[0043] In an optional embodiment, the welding gun 18 is a MIG welding gun or a MAG welding gun, and the welding gun 2 19 is a TIG welding gun.

[0044] It should be noted that MIG / MAG welding is a commonly used gas shielded welding method, which uses inert gas (such as argon) or active gas (such as carbon dioxide or a mixture of argon and carbon dioxide) as a protective medium to prevent the welding area from being contaminated by harmful gases such as oxygen and nitrogen in the air. This method is suitable for welding a variety of materials, including carbon steel, stainless steel, aluminum alloy, etc.; TIG welding is a non-melting electrode gas shielded welding method, which uses tungsten as an electrode and protects the welding area with an inert gas (such as argon). This method is suitable for welding thin plates, precision components, and high-demand welds.

[0045] In an optional embodiment, a camera 22 and a barcode scanner 23 are installed at the front end of the welding workstation 11. The camera 22 is located between the ambient temperature sensor 21 and the barcode scanner 23. The barcode scanner 23 is used to scan the QR code and bind and store the welding data. Alarm lights 26 are installed on the top of both sides of the welding workstation 11, and the camera 22 is electrically connected to the alarm lights 26.

[0046] It should be noted that the camera 22 can identify workpiece errors, and the alarm light 26 can issue an alarm in time when an error is identified.

[0047] like Figure 5 As shown, a method for operating a drive disc assembly combined welding machine comprises the following steps:

[0048] S1: First, the workpiece is loaded onto the workbench 15 located at the position of the welding station 12, and the workpiece is clamped by the fixture 16. The barcode scanner 23 scans the QR code and binds and stores the welding data. The camera 22 performs workpiece recognition. If the recognition is correct, continue. Otherwise, the alarm light 26 is triggered and the operation is terminated.

[0049] S2: Then, the workbench 15 at the position of the welding station 12 is rotated to the welding station 13 by using the rotary unit 14. At this time, the workbench 15 previously located at the welding station 13 is rotated to the position of the welding station 12;

[0050] S3: Next, the manipulator 17 is switched to the TIG preheating mode through the PLC controller 30, and the welding gun 2 19 discharges and heats the material in the welding area; then the manipulator 17 is switched to the MIG or MAG welding mode, and welding is performed through the welding gun 1 18; after the welding is completed, the manipulator 17 is switched to the TIG insulation mode, and the welding gun 2 19 discharges and heats the welding area. During the insulation stage, the welding area temperature sensor 20 monitors and feeds back the temperature of the welding area after welding in real time;

[0051] S4: During the welding process, another workbench 15 prepares the next workpiece on the to-be-welded station 12 and repeats the steps in S1, including workpiece loading, clamping, code scanning and data binding, workpiece identification and error handling;

[0052] S5: After welding is completed, the robot 17 returns to the initial state; the welded workpiece rotates from the welding station 13 to the welding station 12 along with the workbench 15 through the rotary unit 14, ready for unloading; at this time, the workbench 15 and the workpiece thereon that were previously at the welding station 12 rotate to the welding station 13, starting a new round of welding operation, and the above process is repeated.

[0053] like Figure 6 As shown, a method for operating a drive disc assembly combined welding machine, the step S3 further includes:

[0054] S31: presetting key parameters required in the welding process through the PLC controller 30, including but not limited to the current value and feed speed of the initial TIG preheating mode, the current value and feed speed of the initial TIG insulation mode, the current value and voltage value of the MIG or MAG welding mode, the expected welding area temperature after preheating, the expected temperature of the welding area, i.e., the welding point, before insulation begins, and the target temperature of the welding area welding point after insulation ends;

[0055] S32: Switch the welding gun 19 to the TIG preheating mode to preheat the welding area; the welding area temperature sensor 20 collects the temperature of the welding area after preheating in real time, and compares the data with the preset temperature. According to the temperature difference, the PLC controller 30 adjusts the preheating current and feed speed of the next cycle: if the measured temperature is lower than the preset value, the preheating current is increased and the feed speed is appropriately reduced to enhance the preheating effect;

[0056] S33: After preheating is completed, switch the welding gun 18 to MIG or MAG welding mode, and perform welding operations according to preset current and voltage parameters;

[0057] S34: When welding is about to end or immediately after it is finished, the temperature of the area to be kept warm is measured by the welding area temperature sensor 20, and the measured temperature is compared with the preset temperature before keeping warm. The current or feed speed of the welding gun 19 is adjusted according to the temperature difference to prepare for the keeping warm stage. If the measured temperature is higher than the preset value, the current is appropriately reduced or the feed speed is increased; if the measured temperature is lower than the preset value, the temperature difference is converted into the adjustment amount of the current and feed speed in the preheating stage for use in the next cycle;

[0058] S35: Switch the welding gun 19 to the TIG insulation mode to perform discharge insulation treatment on the welding area; after the insulation is completed, use the welding area temperature sensor 20 to measure the temperature of the welding area again, and compare it with the preset temperature after insulation; according to the temperature difference, the PLC controller 30 adjusts the current and feed speed of the welding gun 19 in the next cycle to ensure the continuous stability of the welding quality.

[0059] The above is only a specific implementation of the present disclosure, but the protection scope of the present disclosure is not limited thereto. Any person skilled in the art who is familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present disclosure, which should be included in the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be based on the protection scope of the claims.

Claims

1. A drive disc assembly combined welding machine, characterized in that: The invention comprises a welding workstation (11), wherein a welding station (12) is arranged at the front end of the welding workstation (11), a welding station (13) is arranged inside the welding workstation (11), a rotating unit (14) is arranged in the middle of the welding station (12) and the welding station (13), two workbenches (15) are symmetrically arranged on the rotating unit (14), one of the workbenches (15) is located at the welding station (12), and the other workbenches (15) is located at the welding station (13), a fixture (16) is arranged on the workbenches (15), three manipulators (17) are arranged in a circular distribution with the welding station (13) as the center inside the welding workstation (11), one of the manipulators (17) is suspended and installed inside the welding workstation (11) to avoid interfering with the normal operation of the rotating unit (14), and each of the manipulators (17) is simultaneously installed with a welding gun 1 (18) and a welding gun 2 (19).

2. A drive disc assembly combined welding machine according to claim 1, characterized in that: A welding power source 1 (27) and a welding power source 2 (28) are installed at the upper end of the welding workstation (11); the welding power source 1 (27) is used to supply power to a welding gun 1 (18); the welding power source 2 (28) is used to supply power to a welding gun 2 (19); and a guardrail (29) is fixed around the welding power source 1 (27) and the welding power source 2 (28) at the upper end of the welding workstation (11).

3. A drive disc assembly combined welding machine according to claim 2, characterized in that: An ambient temperature sensor (21) is installed at the front end of the welding workstation (11), and a welding area temperature sensor (20) is installed on the manipulator (17). The ambient temperature sensor (21) and the welding area temperature sensor (20) are connected to a control system provided inside a PLC controller (30). The PLC controller (30) is installed on one side of the front end of the welding workstation (11). The PLC controller (30) is electrically connected to the manipulator (17) and welding gun 1 (18) and welding gun 2 (19) installed on the manipulator (17).

4. A drive disc assembly combined welding machine according to claim 3, characterized in that: A plurality of cameras (25) are arranged inside the welding workstation (11), a monitoring display (24) is arranged at the front end of the welding workstation (11), and the cameras (25) are connected to the monitoring display (24).

5. The drive disc assembly combined welding machine according to claim 3, characterized in that: The first welding gun (18) is a MIG welding gun or a MAG welding gun, and the second welding gun (19) is a TIG welding gun.

6. The drive disc assembly combined welding machine according to claim 3, characterized in that: A camera (22) and a barcode scanner (23) are installed at the front end of the welding workstation (11); the camera (22) is located between the ambient temperature sensor (21) and the barcode scanner (23); the barcode scanner (23) is used to scan a two-dimensional code and bind and store welding data; warning lights (26) are installed at the top of both sides of the welding workstation (11); and the camera (22) is electrically connected to the warning lights (26).

7. An operating method of a drive disc assembly combined welding machine according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: First, the workpiece is loaded onto a workbench (15) located at the position of the welding station (12), and the workpiece is clamped by a fixture (16). The barcode scanner (23) scans the QR code and stores the welding data in a binding manner. The camera (22) performs workpiece recognition. If the recognition is correct, the process continues. Otherwise, an alarm light (26) is triggered and the operation is terminated. S2: Then, the workbench (15) at the position of the welding station (12) is rotated to the position of the welding station (13) by using the rotating unit (14). At this time, the workbench (15) previously located at the welding station (13) is rotated to the position of the welding station (12); S3: Next, the manipulator (17) is switched to the TIG preheating mode through the PLC controller (30), and the welding gun (2) (19) discharges and heats the material in the welding area; then the manipulator (17) is switched to the MIG or MAG welding mode, and welding is performed through the welding gun (18); after the welding is completed, the manipulator (17) is switched to the TIG insulation mode, and the welding gun (2) (19) discharges and heats the welding area. During the insulation stage, the welding area temperature sensor (20) monitors and feeds back the temperature of the welding area after welding in real time; S4: During the welding process, another workbench (15) prepares the next workpiece on the welding station (12) and repeats the steps in S1, including workpiece loading, clamping, code scanning and data binding, workpiece identification and error handling; S5: After welding is completed, the robot (17) returns to the initial state; the welded workpiece rotates from the welding station (13) to the waiting welding station (12) along with the workbench (15) through the rotary unit (14) to prepare for unloading; at this time, the workbench (15) previously at the waiting welding station (12) and the workpiece thereon rotate to the welding station (13), starting a new round of welding operation, and the above process is repeated.

8. The method for operating a drive disc assembly combined welding machine according to claim 7, characterized in that: The S3 step further includes: S31: presetting key parameters required in the welding process through the PLC controller (30), including but not limited to the current value and feed speed of the initial TIG preheating mode, the current value and feed speed of the initial TIG insulation mode, the current value and voltage value of the MIG or MAG welding mode, the expected welding area temperature after preheating, the expected temperature of the welding area (i.e., the welding spot) before insulation begins, and the target temperature of the welding area (welding spot) after insulation ends; S32: Switch welding gun 2 (19) to TIG preheating mode to preheat the welding area; the welding area temperature sensor (20) collects the temperature of the welding area after preheating in real time, and compares the data with the preset temperature. According to the temperature difference, the PLC controller (30) adjusts the preheating current and feed speed of the next cycle: if the measured temperature is lower than the preset value, the preheating current is increased and the feed speed is appropriately reduced to enhance the preheating effect; S33: After preheating is completed, switch the welding gun 1 (18) to MIG or MAG welding mode and perform welding operations according to preset current and voltage parameters; S34: When welding is about to end or immediately after it ends, the temperature of the area to be kept warm is measured by the welding area temperature sensor (20), the measured temperature is compared with the preset temperature before keeping warm, and the current or feed speed of the second welding gun (19) is adjusted according to the temperature difference to prepare for the keeping warm stage. If the measured temperature is higher than the preset value, the current is appropriately reduced or the feed speed is increased; if the measured temperature is lower than the preset value, the temperature difference is converted into the adjustment amount of the current and feed speed in the preheating stage to prepare for the next cycle; S35: Switch welding gun 2 (19) to TIG insulation mode to perform discharge insulation treatment on the welding area; after the insulation is completed, use the welding area temperature sensor (20) to measure the temperature of the welding area again and compare it with the preset temperature after insulation; according to the temperature difference, the PLC controller (30) adjusts the current and feed speed of welding gun 2 (19) in the next cycle to ensure the continuous stability of welding quality.

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