A welding test system and test method based on multi-specification test plates

Abstract

The application provides a welding test system and method based on multi-specification test plates, which comprises a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking tool and a plurality of welding tools; the multi-channel welding system comprises a plurality of wire feeders and a plurality of welding guns; the electrical control system is in electrical communication with the welding power source and the multi-channel welding system respectively, the automatic welding system is in electrical connection with the electrical control system and connected with each welding gun, and the stacking tool is configured to adjustably support the test plates, and each welding tool is provided with a reverse deformation support, which adjusts the reverse deformation angle of the test plates during the welding process of the automatic welding system controlling the welding guns to weld the plurality of test plates in a first state. The test system provided by the application is matched with the same welding power source and tool design, and can weld test test plates of different specifications without changing the welding parameters, thereby ensuring the stability and consistency of welding, and improving the precision and efficiency of welding.

Description

Technical Field

[0001] This application relates to the field of welding testing, and in particular to a welding testing system and method based on multi-specification test plates. Background Technology

[0002] In pipeline construction, welding wire testing is a crucial means of ensuring the pass rate of on-site pipeline construction. Traditional welding wire testing mainly involves manual welding, which often requires the simultaneous use of multiple welding power sources to meet time constraints. Each welding power source typically requires its own wire feeder, welding torch, and welding wire of a specific specification. This testing method has several drawbacks: manual welding cannot guarantee stability, and when welding results deviate from expectations, it is impossible to determine whether the problem lies with manual operation or the welding wire; the lack of uniformity in welding power sources makes it difficult to pinpoint the root cause of welding problems; during the welding process, changes in the size of the test plate lead to poor precision in manual anti-deformation control, and the welding parameters cannot adapt to changes in the size of the test plate, affecting weld formation and quality. Summary of the Invention

[0003] To address the aforementioned issues, this invention provides a welding testing system and method based on multi-specification test plates. This system provides a stable welding trajectory for welding wire testing, uses the same welding power source and mechanical tooling design, and can weld test plates of different specifications without changing welding parameters. It ensures welding stability and consistency, improves welding accuracy and efficiency, reduces labor costs, and improves the working environment.

[0004] The technical solution of this invention is:

[0005] The first aspect of the present invention provides a welding test system based on multi-specification test plates, including a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking fixture, and multiple welding fixtures;

[0006] The multi-channel welding system includes multiple wire feeders and multiple welding torches, with each wire feeder connected to a specific welding torch, and each wire feeder equipped with welding wire of different specifications; wherein,

[0007] The electrical control system is electrically connected to both the welding power source and the multi-channel welding system to control multiple welding torches to weld welding wires of corresponding specifications onto multiple test plates of different specifications under different welding conditions; wherein the multiple test plates of different specifications are respectively fixed on multiple welding fixtures; and,

[0008] The automatic welding system is electrically connected to the electrical control system and to each of the welding torches to automatically control each welding torch to move with preset welding parameters;

[0009] The stacking fixture is configured to adjustably support the test plate so that the automatic welding system can control the welding torch to melt and clad the weldable ends of multiple test plates to the first state.

[0010] Each of the welding fixtures is provided with an anti-deformation support, which is configured to adjust the anti-deformation angle of the test plate during the welding process of the automatic welding system controlling the welding torch to weld multiple test plates in the first state.

[0011] Optionally, the welding conditions include at least one of welding current, welding voltage, and wire feed speed; the welding parameters include at least one of welding speed, welding direction, welding distance, welding angle, and welding trajectory.

[0012] Optionally, the stacking fixture includes:

[0013] A base for placing on the worktable;

[0014] A support base, located above the base, is used to support at least one of the test plates;

[0015] The lifting mechanism is connected to the base and the support seat at its upper and lower ends, respectively.

[0016] The lead screw has a support rod sleeved on its outer periphery and a movable rod for transmission connection;

[0017] A handwheel, connected to the end of the lead screw, applies rotational torque to rotate the lead screw, thereby driving the movable rod to reciprocate along the axial direction of the lead screw.

[0018] The lifting mechanism is hinged to the movable rod and the support rod respectively; when the movable rod moves toward the handwheel, the lifting mechanism drives the support seat to rise; when the movable rod moves away from the handwheel, the lifting mechanism drives the support seat to fall.

[0019] Optionally, the lifting mechanism includes two telescopic components arranged opposite to each other. Each telescopic component includes two symmetrically intersecting and horizontally placed V-shaped rods. The closed end of one V-shaped rod is hinged to the movable rod, and the closed end of the other V-shaped rod is hinged to the support rod. The intersection of the two V-shaped rods is hinged together.

[0020] The base and the support have sliding grooves on their side walls, and the two ends of the V-shaped rod that is hinged to the movable rod are respectively located in the sliding grooves.

[0021] Optionally, the support base is provided with at least one clamp, each clamp having a trapezoidal space for clamping the test plate.

[0022] Optionally, each of the welding fixtures further includes two symmetrically spaced positioning plates, which are used to abut against one side of the two test plates respectively;

[0023] The anti-deformation support is located between the two positioning plates and is used to simultaneously abut against the welding end faces of the two test plates.

[0024] The height of the anti-deformation support is greater than the height of the positioning plate to counteract the deformation angle of the test plate during welding.

[0025] Optionally, each of the positioning plates has at least one positioning groove, and a positioning pin is inserted into each positioning groove; wherein, the positioning groove extends from one side of the positioning plate toward the anti-deformation support.

[0026] Optionally, each of the welding fixtures also includes a positioning ruler.

[0027] Optionally, the anti-deformation support is provided with fixing grooves on opposite sides, and each fixing groove is used to engage the end face to be welded of the corresponding test plate.

[0028] Compared with the prior art, this application has the following advantages:

[0029] The welding testing system based on multi-specification test plates proposed in this invention includes a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking fixture, and multiple welding fixtures. The multi-channel welding system includes multiple wire feeders and multiple welding torches, with each wire feeder connected to a corresponding welding torch, and each wire feeder equipped with welding wire of different specifications. The electrical control system is electrically connected to both the welding power source and the multi-channel welding system to control the multiple welding torches to weld the corresponding specifications of welding wire onto multiple test plates of different specifications under different welding conditions. Each welding fixture is fixed to one of the welding fixtures respectively; and the automatic welding system is electrically connected to the electrical control system and to each welding torch to automatically control each welding torch to move with preset welding parameters; wherein, the stacking fixture is configured to adjustably support the test plate so that the automatic welding system controls the welding torch to melt the end faces of the multiple test plates to be welded to a first state; wherein, each welding fixture is provided with an anti-deformation support, the anti-deformation support being configured to adjust the anti-deformation angle of the test plate during the welding process of the multiple test plates in the first state controlled by the automatic welding system.

[0030] The multifunctional welding system and electrical control system provided by the embodiments of the present invention can be equipped with different welding wires and corresponding welding guns for each wire feeder. It can simultaneously achieve welding of test plates of various specifications by one welding power source, avoiding the influence of inconsistent welding power sources on the welding wire test results. Furthermore, welding wire tests can be performed on test plates of various specifications at the same time without the need to change the contact tip of the welding gun, thus improving the timeliness of welding work and the efficiency of welding testing.

[0031] The automatic welding system and stacking fixture provided in this embodiment of the invention solve the problems of welding stability and point accuracy, thereby avoiding the influence of human factors on the welding test results during manual welding testing. At the same time, the stacking fixture adopts a liftable method to accurately control the cross-sectional height of the test plate to be stacked. Using the same welding program, there is no need to change the welding parameters, which reduces costs.

[0032] The welding fixture provided in this embodiment of the invention allows for the adjustment of the height of the anti-deformation support to counteract the deformation angle of test plates of different specifications for multiple test plates of different widths. This achieves the anti-deformation effect without changing the welding parameters and using the same welding procedure, thus ensuring the reliability and consistency of the welding.

[0033] The second aspect of the present invention also provides a testing method for welding multi-specification test plates, which utilizes the welding testing system based on multi-specification test plates provided in the first aspect of the present invention for welding.

[0034] The testing method described above has the same advantages over existing technologies as the welding testing system described above, and will not be repeated here. Attached Figure Description

[0035] To more clearly illustrate the technical solution of this application, the drawings used in the description of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the working principle of the welding test system based on multi-specification test plates described in this application;

[0037] Figure 2 This is a front view of the stacking fixture described in one embodiment of this application;

[0038] Figure 3 This is a schematic diagram of the overall structure of the welding fixture described in another embodiment of this application;

[0039] Figure 4 This is a top view of the welding fixture described in another embodiment of this application.

[0040] Explanation of reference numerals in the attached figures:

[0041] 1. Handwheel; 2. Lead screw; 3. Movable rod; 4. Support rod; 5. Support seat; 6. Base; 7. Telescopic assembly; 8. Slide groove; 9. Anti-deformation support; 10. Positioning plate; 11. Positioning groove; 12. Test plate; 13. Positioning pin; 121. End face to be welded. Detailed Implementation

[0042] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0043] It should be noted that in welding quality and safety testing, welding wire is the main filler material in the welding process, and its quality directly affects the strength, sealing performance, and corrosion resistance of the welded joint. Welding wire testing can detect the quality and performance of the welding wire to ensure welding quality and safety. Welding wire testing includes various test items, including mechanical property testing and chemical analysis of the welding wire before welding, as well as verification testing before actual pipeline welding. In this invention, by welding the welding wire to the substrate to form a welded joint, the performance of the welded joint is tested to simulate the performance of the welding wire in the actual welding process.

[0044] It is understood that the test plate 12 mentioned in this article is the substrate to be welded. During the welding wire testing process, the specifications of the test plate 12 change, mainly manifested in the fact that the width of the test plate 12 shortens as the number of tests increases. Therefore, in actual testing, it is often necessary to use test plates 12 of different specifications for welding wire testing.

[0045] In actual testing, the main shortcomings are manifested in at least four aspects:

[0046] 1. Manual welding is easily affected by factors such as the operator's skill level and experience, resulting in unstable welding quality. Defects such as uneven welds, porosity, slag inclusions, and cracks in the weld joints cannot be directly determined to be problems with the quality and performance of the welding wire.

[0047] 2. Test plates 12 of different specifications usually need to be matched with welding wires of different specifications, welding currents and / or voltages. Therefore, each specification of test plate 12 corresponds to specific welding requirements. The welding power source needs to be adjusted according to the welding requirements. However, a welding power source can only output a fixed current and voltage at the same time to power a wire feeder. A wire feeder can only output a type of welding wire. Therefore, for welding wire testing of test plates 12 of different specifications, matching multiple welding power sources cannot guarantee the uniformity of welding conditions and is prone to misjudgment of welding wire quality and performance issues.

[0048] 3. Thermal stress and thermal strain will be generated during the welding process, causing the test plate 12 to warp, twist, shrink and other deformations. Relying solely on the operator's welding experience to control the deformation will result in poor deformation control and affect the judgment of the quality and performance of the welding wire.

[0049] 4. The welding conditions and welding parameters required for different specifications of test plates 12 need to be changed accordingly. However, the welding parameters of the robot are fixed and cannot accurately and stably control the movement trajectory of the welding torch to adapt to different specifications of test plates 12, resulting in the position of the welded joint being offset or the welding quality being unstable.

[0050] In view of this, in order to address the aforementioned shortcomings, refer to Figure 1 As shown, Figure 1 This is a schematic diagram of the overall structure of the automated material storage for the access node instrument shown in this invention. An embodiment of this invention provides a welding test system based on multi-specification test plates 12, including a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking fixture, and multiple welding fixtures. The multi-channel welding system includes multiple wire feeders and multiple welding torches, each wire feeder being connected to each welding torch in a one-to-one correspondence, and each wire feeder being equipped with welding wire of different specifications. The electrical control system is electrically connected to both the welding power source and the multi-channel welding system to control the multiple welding torches to weld the corresponding specifications of welding wire onto multiple test plates 12 of different specifications under different welding conditions. The multiple test plates 12 of different specifications are respectively... The welding fixture should be fixed on multiple welding fixtures; and the automatic welding system is electrically connected to the electrical control system and to each welding torch to automatically control each welding torch to move with preset welding parameters; wherein the stacking fixture is configured to adjustably support the test plate 12 so that the automatic welding system controls the welding torch to melt the end faces 121 of the multiple test plates 12 to be welded to a first state; wherein each welding fixture is provided with an anti-deformation support 9, the anti-deformation support 9 being configured to adjust the anti-deformation angle of the test plate 12 during the welding process of the multiple test plates 12 in the first state controlled by the automatic welding system.

[0051] Specifically, the welding testing system is assembled from a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking fixture, and multiple welding fixtures. As a whole system, it can simultaneously handle various specifications of welding wire and the setting of welding conditions and parameters. The welding power source can be understood as a device that provides stable current and voltage to ignite the arc in the welding torch and melt the welding wire. The wire feeder controls the feeding speed and direction of the welding wire, responsible for feeding the welding wire from the reel or box into the welding torch. The welding torch is the component connecting the power source and the welding wire. During the welding process, it melts the welding wire through the arc and applies it to the bevel, thereby fusing with the bevel of the test plate 12 to form a welded joint.

[0052] Specifically, the welding power source can be connected to the wire feeder and welding torch via different cables. The wire feeder and welding torch can be connected by a flexible hose containing the welding wire, shielding gas, and cable. The wire feeder feeds the welding wire from the reel into the hose, and then delivers it to the contact tip of the welding torch. Each wire feeder is equipped with a specific specification of welding wire, and multiple wire feeders can feed welding wires of various specifications into multiple welding torches.

[0053] In this embodiment, the welding power source and multiple wire feeders are respectively connected to the electrical control system, allowing one welding power source to control the welding conditions for multiple wire feeders at the same time, adapting to the welding wire testing requirements of different specifications of test plates 12, and enabling multiple specifications of welding wire to be correctly melted and uniformly coated on the bevel of multiple specifications of test plates 12 within the same time period.

[0054] In some embodiments, the electrical control system is connected to a display screen, which can switch to the corresponding working mode according to the operator's selection on the display screen. Simultaneously, it monitors and controls the welding process, measuring and displaying various parameters during the welding process, such as current, voltage, temperature, and pressure.

[0055] Specifically, the appropriate welding wire specifications and types can be determined first based on the test plate parameters such as specifications, material, bevel form, and weld arrangement of the test plate 12, and a wire feeder with corresponding welding wire can be selected. The electrical control system automatically adjusts the welding conditions according to the input test plate parameters and welding wire parameters such as specifications, composition, and performance to adapt to the welding needs of test plates 12 of different specifications. The welding conditions include welding current, welding voltage, wire feeding speed, and shielding gas. That is, the electrical control system controls multiple wire feeders at different wire feeding speeds and multiple welding torches at different welding currents and welding voltages to melt the corresponding welding wire and test plate 12 for different specifications of test plates 12.

[0056] It is understood that, apart from the different specifications, the test plate 12 and the welding wire of the present invention have the same parameters.

[0057] For example, such as Figure 1 As shown, Figure 1 This is a schematic diagram illustrating the working principle of the welding test system based on multi-specification test plates 12 according to the present invention. The multi-channel welding system includes a wire feeder, a wire feeder, a wire feeder, a welding torch, and a welding torch. The wire feeder is connected to the welding torch, the wire feeder is connected to the welding torch, and the welding torch is connected to the welding torch. The welding torch corresponds to the welding fixture, the welding torch corresponds to the welding fixture, and the welding torch corresponds to the welding fixture. The welding fixture can hold a 240mm wide test plate 12, the welding fixture can hold a 280mm wide test plate 12, and the welding fixture can hold a 300mm wide test plate 12. The welding power supply, the three wire feeders, and the three welding torches are respectively connected to the electrical control system, which determines the working mode of the three wire feeders and the corresponding welding torches according to the usage conditions.

[0058] Therefore, during the welding wire testing process, after selecting the position of the welding fixture, the test plate specification, and the welding wire specification on the display screen, the electrical control system switches to the corresponding wire feeder. It can be set to use only one wire feeder, any two wire feeders, or all three wire feeders. Each wire feeder is equipped with different welding wires and corresponding welding torches, allowing for simultaneous welding of multiple test plates 12 specifications with a single welding power source. This avoids the impact of inconsistent welding power sources on the welding wire test results and allows for welding wire testing of multiple test plates 12 specifications within the same time period without the need to change the welding torch's contact tip, improving the timeliness and efficiency of the welding work.

[0059] More specifically, when the electrical control system initiates or stops welding by calling the wire feeder and corresponding welding torch, the automatic welding system automatically controls the action of the welding torch according to the preset welding program and parameters, replacing the operator to complete the welding. This eliminates the need for manual intervention, achieving efficient and stable automatic welding. It solves the problems of welding stability and point accuracy, thus avoiding the influence of human factors on welding test results during manual welding testing.

[0060] Specifically, an automated welding system can be an automated welding robot. A robot is a mechanical device with multiple degrees of freedom, programmable, and capable of repeatable movements, mimicking the welding operations of a human arm and fingers. The robot is connected to both a welding torch and an electrical control system. Typically, the robot's end effector holds the welding torch, and the electrical control system acts as the robot's control cabinet, controlling the robot's welding parameters, thereby causing the welding torch to move along preset welding parameters during the welding process. These welding parameters include at least one of welding speed, welding direction, welding distance, welding angle, and welding trajectory.

[0061] It should be understood that robotic welding is a common welding operation. Through pre-programmed welding procedures and path planning, combined with feedback information from sensors and electrical control systems, the welding torch is controlled to move along a set trajectory, speed, and posture at the bevel of the test plate 12.

[0062] To explain this in detail, the robot executes a walking trajectory, controlling the robot's positioning and trajectory accuracy to within ±0.05. The welding path is determined through manual programming. The robot moves and operates within the work area according to a specific trajectory based on the pre-programmed path and motion plan. The welding trajectory can be a straight line, a curve, or a complex multi-segment path. The robot executes stably in three-dimensional space, solving the problems of welding speed stability and point accuracy, improving testing efficiency and quality, and reducing labor costs.

[0063] To explain this in more detail, the robot can be configured with a positioning function, with an accuracy within ±0.05mm. This positioning function enables the robot to automatically identify and locate the test plate 12 in the work environment, thereby adjusting its posture and position. Manual programming may not result in accurate wire extension; the configured positioning function ensures accurate wire extension. Accurate wire extension stabilizes the actual welding current and voltage, guaranteeing stable heat input (which affects welding deformation) and dimensional stability of the weld.

[0064] As we know, the robot's welding trajectory is usually fixed. When the specifications of the test plate 12 change, it directly affects the welding parameters such as the robot's welding trajectory and welding speed during the welding process. If it is necessary to change the robot's welding parameters, the robot's programming needs to be adjusted.

[0065] In this embodiment of the invention, a plating fixture is provided to facilitate the plating of the test plate 12 by the welding torch. Specifically, the change in the specifications of the test plate 12 refers to the shortening of its width as the number of welding operations increases, while the length and thickness of the test plate 12 are usually fixed. Therefore, for a test plate 12 with a shortened width, such as a test plate 12 with a width of 240mm-300mm, its height on the plating fixture during the plating process will be different. Since the robot's welding trajectory is fixed, the plating position of the test plate 12 will deviate. By utilizing the adjustable characteristics of the plating fixture, the height of test plates 12 with different widths on the plating fixture can be made the same, thus adapting to the robot's welding trajectory.

[0066] It is understandable that cladding can strengthen and repair the weldable end face 121 of the test plate 12, so that it has better wear resistance, heat resistance, and corrosion resistance in subsequent welding processes. The weldable end face 121 refers to the side of the test plate 12 where the welding groove is formed. Typically, the weldable end face 121 of the test plate 12 is a bevel, so that when two test plates 12 are placed opposite each other, a V-shaped groove is formed, and the welding wire melts and fills the V-shaped groove to form a welded joint.

[0067] The test plate 12 is typically placed vertically on the stacking fixture, with the end face 121 to be welded located at the top as the top surface, facilitating robotic cladding. Because the test plates 12 have varying widths, their heights differ when placed vertically, resulting in multiple test plates 12 having their end faces 121 at different horizontal heights. To address the varying widths of the test plates 12, the stacking fixture is modified, comprising:

[0068] The base 6, as the load-bearing part of the entire device, is used to support the various components and at least one test plate 12 to be clad. The support 5 is located above the base 6 and is connected to the base 6 through a lifting mechanism. By the lifting movement of the lifting mechanism, the support 5 rises when the distance between it and the base 6 increases and falls when the distance decreases, thereby realizing the height adjustment of the support 5.

[0069] For example, if the support base 5 is in the unraised state, the robot's welding parameters are suitable for welding a 300mm wide test plate 12. Therefore, when it is necessary to clad a 240mm wide test plate 12, the 240mm wide test plate 12 can be placed vertically on the support base 5, and the support base 5 can be raised to increase the height of the test plate 12 until the top surface of the 240mm wide test plate 12 is at the same height as the top surface of the 300mm wide test plate 12. After the cladding of the 240mm wide test plate 12 is completed, the corresponding test plate 12 can be removed and a 260mm wide test plate 12 can be placed. At this time, the support base 5 can be lowered appropriately to reduce the height of the test plate 12 until the top surface of the 260mm wide test plate 12 is at the same height as the top surface of the 300mm wide test plate 12.

[0070] Each cladding process should involve placing a test plate 12 of the same specification on the support base 5.

[0071] To elaborate further, please refer to Figure 2 , Figure 2 This is a front view of the stacking fixture shown in this invention. The lifting mechanism is connected to the lead screw 2 via a support rod 4 and a movable rod 3. A handwheel 1 is provided at the end of the lead screw 2. By manually rotating the handwheel 1, the lead screw 2 is rotated. The movable rod 3 is sleeved on the outer periphery of the lead screw 2. The two form a ball screw 2 mechanism. The rotational motion of the lead screw 2 is converted into the axial motion of the movable rod 3, thereby causing the movable rod 3 to slide on the lead screw 2.

[0072] Specifically, the lifting mechanism includes two telescopic components 7 arranged opposite each other. Each telescopic component 7 includes two symmetrically intersecting and horizontally placed V-shaped rods. The closed end of one V-shaped rod is hinged to the movable rod 3, and the closed end of the other V-shaped rod is hinged to the support rod 4. The intersection of the two V-shaped rods is hinged together. The side walls of the base 6 and the support 5 are provided with sliding grooves 8, and the two ends corresponding to the open ends of the V-shaped rods hinged to the movable rod 3 are respectively movably located in the sliding grooves 8.

[0073] Two opposing telescopic components 7 are hinged to opposite sides of the support rod 4 and the movable rod 3, forming a cross-hinged structure on the same side. The openings of the two V-shaped rods face each other and extend laterally. Each V-shaped rod includes two angled supports; one end of each support of one V-shaped rod is hinged to the movable rod 3, and the two supports of the other V-shaped rod are hinged to the support rod 4. The free ends of the two supports hinged to the movable rod 3 are movably connected to the base 6 and the support seat 5, respectively, while the free ends of the two supports hinged to the support rod 4 are fixedly connected to the base 6 and the support seat 5, respectively.

[0074] Since the two ends of the V-shaped rod are supported on the base 6 and the support seat 5 respectively, when the movable rod 3 moves closer to the support rod 4, the two ends of one V-shaped rod slide forward within the grooves 8 of the base 6 and the support seat 5. The two ends of both V-shaped rods are subjected to force, and the closed end of the V-shaped rod has a hinge point, which increases the angle between the two supports forming the V-shaped rod. In other words, the opening of the V-shaped rod gradually increases, increasing the distance between the base 6 and the support seat 5, thus raising the height of the support seat 5. Conversely, when the movable rod 3 moves away from the support rod 4, the two ends of one V-shaped rod slide backward within the grooves 8 of the base 6 and the support seat 5 respectively. The two ends of both V-shaped rods are subjected to force, and the closed end of the V-shaped rod has a hinge point, decreasing the angle between the two supports forming the V-shaped rod. In other words, the opening of the V-shaped rod gradually decreases, reducing the distance between the base 6 and the support seat 5, thus lowering the height of the support seat 5.

[0075] The two V-shaped rods are hinged at their intersection, allowing them to move synchronously. In some embodiments, the two opposing telescopic components 7 can be connected as a whole by multiple fixed rods. For example, the intersection of two V-shaped rods on the same side is hinged to one end of a fixed rod, and the intersection of two V-shaped rods on the other side is hinged to the other end of the same fixed rod. In some embodiments, the V-shaped rods sliding on both sides of the base 6 are connected by a fixed rod. In some embodiments, the V-shaped rods sliding on both sides of the support 5 are connected by a fixed rod.

[0076] At least one clamp is provided on the support base 5, and each clamp has a trapezoidal space for holding the test plate 12. In this embodiment, the clamp consists of two opposing clamping plates, one of which gradually tilts towards the other, forming a trapezoidal space that is wider at the bottom and narrower at the top. The test plate 12 is placed vertically within this trapezoidal space, with the end face 121 to be welded located at the top. Since the end face 121 to be welded of each test plate 12 is an inclined plane, forming an angle with the horizontal plane, and the robot's welding trajectory is usually horizontal cladding, the clamp is provided on the support base 5. When the test plate 12 is installed in the trapezoidal space, the test plate 12 forms a certain angle with the horizontal plane of the support base 5, making the end face 121 to be welded of the test plate 12 flush with the horizontal plane, thereby achieving horizontal cladding by the robot.

[0077] Preferably, a scale can be set on the stacking fixture to calibrate the placement height of the test plate 12.

[0078] In practice, when the handwheel 1 rotates clockwise, it drives the lead screw 2 to rotate, and the movable rod 3 moves forward along the helical direction of the lead screw 2. The movable rod 3 moves forward along the helical direction of the threaded rod, pushing the V-shaped rod to increase the angle along the hinge point, causing the support seat 5 to rise, thus raising the test plate 12. When the movable rod 3 rotates counterclockwise, it moves backward along the helical direction of the lead screw 2, pushing the V-shaped rod to decrease the angle along the hinge point, causing the support seat 5 to fall, thus lowering the test plate 12.

[0079] Thus, the stacking fixture adopts a liftable design, precisely controlling the cross-sectional height of the test plates 12 to be stacked. When using the same stacking program to place test plates 12 of different widths, the height of the stacking fixture can be adjusted. Compared to adapting to test plates 12 of different widths by adjusting the welding program, which involves more welding programs, higher power consumption, and poorer stability, the stacking fixture, by adjusting the height of the support base 5, keeps the welding end faces 121 of test plates 12 of different widths at the same height. This allows the robot to use the same welding program to weld test plates 12 of different widths in batches, simplifying robot programming and control, and reducing costs and maintenance.

[0080] Please see Figure 3 and Figure 4 , Figure 3 and Figure 4 The figures shown are an isometric view and a top view of the welding fixture shown in this invention.

[0081] In another embodiment, each welding fixture further includes two symmetrically spaced positioning plates 10, which abut against one side of each of the two test plates 12. The anti-deformation support 9 is located between the two positioning plates 10 and abuts against the welding end faces 121 of both test plates 12 simultaneously. The height of the anti-deformation support 9 is greater than the height of the positioning plates 10 to counteract the deformation angle of the test plates 12 during welding. Further, each positioning plate 10 has at least one positioning groove 11, and a positioning pin 13 is inserted into each positioning groove 11. The positioning groove 11 extends from one side of the positioning plate 10 towards the anti-deformation support 9.

[0082] Specifically, during the welding wire testing process, the test plate 12 will experience thermal stress due to the heat input during welding, leading to welding deformation. The deformation angle varies depending on the specifications of the test plates 12. The deformation angle of different specifications of test plates 12 should be less than 5°. Normally, anti-deformation welding control relies on human experience, while robotic welding still requires adjusting welding parameters to change the amount of welding heat input. In this embodiment, an anti-deformation support 9 is provided. By adjusting the height of the anti-deformation support 9, the deformation angle of different specifications of test plates 12 is counteracted, thus achieving an anti-deformation effect.

[0083] Specifically, the positioning plate 10 consists of two test plates 12, each forming a bevel, fixed to each other. The two positioning plates 10 are positioned one in front of the other. The weldable end faces 121 of the two test plates 12 are fixed to the anti-deformation support 9, while the other end faces are placed on the positioning plate 10. The adjacent end faces of the weldable end faces 121 are along the width direction of the test plate 12. Preferably, the anti-deformation support 9 has fixing grooves on opposite sides. Each fixing groove is used to engage the weldable end face 121 of the corresponding test plate 12, ensuring that the weldable end faces 121 of the two test plates 12 are stably fixed to the anti-deformation support 9. The positioning plate 10 can control the gap between the two test plates 12, i.e., the size of the bevel. A positioning scale is also provided along the installation direction of the positioning plate 10. The positioning scale can be fixed to the operating table with bolts. The direction of the positioning scale is the same as the width direction of the test plate 12, and the positioning accuracy fully meets the welding accuracy requirements.

[0084] Once the two test plates 12 are positioned, the locating pin 13 can be fixedly inserted into the locating groove 11, so that the locating pin 13 abuts against the opposite end face of the end face 121 to be welded, ensuring the bevel size during the welding process. The width of the test plate 12 can vary between 240-300mm to ensure the positional deviation of the weld centerline, reducing the skill requirements for personnel and improving the efficiency of the test.

[0085] As a specific explanation of this embodiment, the height of the anti-deformation support 9 can be designed based on practical experience and experimental data.

[0086] Experimental test:

[0087] In this embodiment of the invention, a series of welding wire tests were conducted on test plates 12 of different specifications. The deformation angles of test plates 12 of different widths during the welding process were recorded, as well as the height of the corresponding anti-deformation supports 9. It should be emphasized that the width of the test plates 12 of different specifications was controlled to vary within the range of 240mm-300mm, and the other parameters of the test plates 12 (test plate thickness, test plate length, material, etc.) were the same. At the same time, two sets of tests were conducted on test plates 12 of the same width to ensure accuracy.

[0088] Based on the recorded experimental data, the experimental data were statistically analyzed to obtain the experimental data table as shown in Table 1, which includes the width of the test plate, the deformation angle, and the height of the anti-deformation support.

[0089] Table 1:

[0090]

[0091] Table 1

[0092] As shown in Table 1, adjusting the height of the anti-deformation support 9 can offset the actual deformation angle of the test plate 12. When the deformation angle of the test plate 12 increases, the height of the anti-deformation support 9 can be increased, thereby adjusting the anti-deformation angle of the test plate 12 through the anti-deformation support 9. Based on this, according to experimental data and experience in actual production, the height of the anti-deformation support 9 for test plates 12 with a width range of 240mm-300mm can be obtained to meet the optimal deformation angle. Combined with positioning marks, the test plates 12 of the corresponding width can be placed on the anti-deformation support 9 at an appropriate height. For example, as shown in Table 1, for a test plate 12 with a width of 280mm, the height of the anti-deformation support 9 can be set to 12mm. Therefore, for multiple test plates 12 with a width of 240mm-300mm, the same welding procedure can be used without changing the welding parameters to achieve qualified welding results, ensuring welding reliability and consistency.

[0093] The present invention also provides a testing method for welding multi-specification test plates, which utilizes the welding testing system based on multi-specification test plates described above for welding.

[0094] The above-described test method embodiments are basically similar to the welding test system embodiments, so the description is relatively simple. For relevant details, please refer to the description of the welding test system embodiments.

[0095] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Based on the above embodiments one to five, this application provides some specific examples of implementable methods. Each embodiment is not considered a separate implementable method. Without conflicting with each other, the various embodiments can be arbitrarily combined and interact to form the automated material library of the access node instrument of this application.

[0096] It should be understood that although preferred embodiments of the present application have been described in this specification, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of this application.

[0097] The above provides a detailed description of a welding testing system and method based on multi-specification test plates provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A welding testing system based on multi-specification test plates, characterized in that, The system includes a welding power source, an electrical control system, an automatic welding system, a multi-channel welding system, a stacking fixture, and multiple welding fixtures. The multi-channel welding system includes multiple wire feeders and multiple welding torches, with each wire feeder connected to a specific welding torch, and each wire feeder equipped with welding wire of different specifications. The electrical control system is electrically connected to both the welding power source and the multi-channel welding system to control multiple welding torches to weld welding wires of corresponding specifications onto multiple test plates of different specifications under different welding conditions; wherein the multiple test plates of different specifications are respectively fixed on multiple welding fixtures; and, The automatic welding system is electrically connected to the electrical control system and to each of the welding torches to automatically control each welding torch to move with preset welding parameters; The stacking fixture is configured to adjustably support the test plate so that the automatic welding system can control the welding torch to melt and clad the weldable ends of multiple test plates to the first state. The stacking fixture includes: A base for placing on the worktable; A support base, located above the base, is used to support at least one of the test plates; the support base is provided with at least one clamp, each clamp having a trapezoidal space for clamping the test plate; The lifting mechanism is connected to the base and the support seat at its upper and lower ends, respectively. The lead screw has a support rod sleeved on its outer periphery and a movable rod for transmission connection; A handwheel, connected to the end of the lead screw, applies rotational torque to rotate the lead screw, thereby driving the movable rod to reciprocate along the axial direction of the lead screw. The lifting mechanism is hinged to the movable rod and the support rod respectively; when the movable rod moves toward the handwheel, the lifting mechanism drives the support seat to rise; when the movable rod moves away from the handwheel, the lifting mechanism drives the support seat to fall. Each of the welding fixtures is provided with an anti-deformation support, which is configured to adjust the anti-deformation angle of the test plate during the welding process of the automatic welding system controlling the welding torch to weld multiple test plates in the first state. Each of the welding fixtures further includes two symmetrically spaced positioning plates, which are used to abut against one side of the two test plates respectively; The anti-deformation support is located between the two positioning plates and is used to simultaneously abut against the welding end faces of the two test plates. The height of the anti-deformation support is greater than the height of the positioning plate to counteract the deformation angle of the test plate during welding.

2. The welding testing system based on multi-specification test plates according to claim 1, characterized in that, The welding conditions include at least one of welding current, welding voltage, and wire feed speed; the welding parameters include at least one of welding speed, welding direction, welding distance, welding angle, and welding trajectory.

3. The welding testing system based on multi-specification test plates according to claim 1, characterized in that, The lifting mechanism includes two telescopic components arranged opposite each other. Each telescopic component includes two symmetrically intersecting and horizontally placed V-shaped rods. The closed end of one V-shaped rod is hinged to the movable rod, and the closed end of the other V-shaped rod is hinged to the support rod. The intersection of the two V-shaped rods is hinged together. The base and the support have sliding grooves on their side walls, and the two ends of the V-shaped rod that is hinged to the movable rod are respectively located in the sliding grooves.

4. The welding testing system based on multi-specification test plates according to claim 1, characterized in that, Each of the positioning plates has at least one positioning groove, and a positioning pin is inserted into each positioning groove; wherein, the positioning groove extends from one side of the positioning plate toward the anti-deformation support.

5. The welding testing system based on multi-specification test plates according to claim 1, characterized in that, Each of the aforementioned welding fixtures also includes a positioning ruler.

6. The welding testing system based on multi-specification test plates according to claim 1, characterized in that, The anti-deformation support has fixing grooves on its opposite sides, and each fixing groove is used to engage the end face to be welded of the corresponding test plate.

Images