Automatic grinding system and method for welding electrodes

Abstract

The present invention relates to the technical field of welding electrode grinding, and provides an automatic grinding system and method for welding electrodes, including: a grinding device arranged at a grinding position and an electrode surface detection device arranged at a detection position; wherein, the grinding device includes a grinding rotation mechanism and at least one grinding member connected to the grinding rotation mechanism, and the grinding member is used for grinding the working surface of the first electrode and / or the second electrode to be ground in a state of being driven to rotate by the grinding rotation mechanism; the electrode surface detection device includes a surface finish detection sensor, which is used for detecting the surface finish of the working surface of the ground electrode, so as to judge whether the current grinding is qualified through the surface finish. The present invention can automate the grinding process, reduce the manual operation time, and significantly improve the overall efficiency of the production line; it can avoid the instability of manual electrode grinding, and the surface finish control helps to ensure that the surface of the electrode is flat after each grinding, improving the welding quality.

Description

Technical Field

[0001] The present invention relates to the technical field of welding electrode grinding, and particularly to an automatic grinding system and method for welding electrodes. Background Art

[0002] In the automotive manufacturing industry, a trace-free welding technology - Arplas welding is applied. It stamps out specific protrusions at one end of the overlapping parts, and then uses a welding torch to weld at each dimple position, finally forming a specific welding state. Compared with traditional resistance spot welding, Arplas welding can use less energy to weld the boss positions of parts, and has the advantages of a small heat affected zone and no surface marks. It is commonly used in the areas of automotive door windows and rear water troughs. Since Arplas welding requires stamping bosses before welding, zinc chips often adhere to the workpieces. After multiple weldings, a layer of zinc chips and oxide layers and other dirt will adhere to the electrodes, and the electrode surfaces need to be cleaned regularly to ensure the connection quality of Arplas welding. Arplas electrodes also have round heads and square heads, but for places with a small curvature like the water trough, square electrodes are suitable to ensure a trace-free surface after welding.

[0003] Currently, for the grinding and cleaning of Arplas electrodes, the production line mainly has manual entry into the island. At a frequency of every 30 pieces, P360 grinding discs are used for electrode grinding, resulting in a loss of about 70 minutes of production time per day. For a highly efficient automated production line, manual entry into the island for cleaning is time-consuming and laborious, and also affects the production efficiency of the automated production line. During manual grinding, it is required that the operator has high skills, and the flatness of the upper and lower electrodes must cover the bosses of the welded parts. However, manual grinding easily causes the electrode surfaces to be uneven, affecting the connection quality of the vehicle body surface, and thus also shortening the service life of the electrodes. Summary of the Invention

[0004] In view of this, embodiments of the present invention provide an automatic grinding system and method for welding electrodes to eliminate or improve one or more defects existing in the prior art.

[0005] One aspect of the present invention provides an automatic grinding system for welding electrodes. The welding electrodes include a first electrode and a second electrode installed on a welding torch. The system includes: a grinding device disposed at a grinding position and an electrode surface detection device disposed at a detection position;

[0006] Wherein, the grinding device includes a grinding rotation mechanism and at least one grinding member connected to the grinding rotation mechanism. The grinding member is used to grind the working surfaces of the first electrode and / or the second electrode to be ground in a state of being driven to rotate by the grinding rotation mechanism;

[0007] The electrode surface detection device includes a surface finish detection sensor for detecting the surface finish of the working surface of the electrode after grinding to determine whether the current grinding is qualified based on the surface finish.

[0008] In some embodiments, the welding electrode is controlled by a robot to move in the horizontal and vertical directions to perform welding operations and grinding operations.

[0009] The grinding device further includes a floating unit for floatingly mounting the grinding member such that the floating direction is perpendicular to the working surface of the electrode to be ground.

[0010] The floating unit includes an elastic member or a cylinder for combining the depth of penetration of the electrode to be ground driven by the robot to maintain the pressure between the electrode to be ground and the grinding member at a predetermined pressure under the action of the floating unit.

[0011] In some embodiments, the system further includes a grinding amount control module for controlling the grinding amount of the first electrode and the second electrode by the grinding device in the current grinding operation to be the minimum grinding amount or a predetermined grinding amount.

[0012] The grinding amount control module includes at least one of a grinding pressure control unit, a grinding time control unit, and a grinding member rotation speed control unit.

[0013] Among them, the grinding pressure control unit is used to combine the worn amount of the electrode to be ground and the grinding amount of the current grinding operation to control the depth of penetration of the electrode to be ground driven by the robot, so that the pressure between the electrode to be ground and the grinding member is maintained at a predetermined pressure under the action of the floating unit.

[0014] The grinding time control unit is used to control the grinding time by controlling the residence time of the electrode to be ground at the grinding position by the robot or the start time of the grinding device.

[0015] The grinding member rotation speed control unit is communicatively connected to the grinding rotation mechanism to control the rotation speed of the grinding member according to the grinding amount.

[0016] In some embodiments, the grinding amount control module further includes an electrode wear amount detection unit for detecting the pre-grinding wear amount of the electrode by closing the welding torch before grinding. The wear amount is the difference between the initial height and the current height of the electrode. The pre-grinding wear amount is used to compensate for the depth of penetration control of the first electrode and the second electrode in the current grinding operation to obtain the predetermined pressure.

[0017] The electrode wear amount detection unit is further used to detect the post-grinding wear amount of the electrode by closing the welding torch after grinding. The post-grinding wear amount is used to compensate for the depth of penetration control of the first electrode and the second electrode in the welding operation.

[0018] Wherein, the difference between the wear amount after grinding and the wear amount before grinding is the predetermined grinding amount of this grinding operation;

[0019] The wear amounts of the first electrode and the second electrode after grinding are obtained by using the dichotomy method after detecting the total wear amount by closing the welding torch; or, after one electrode is ground and before the other electrode is ground, the wear amount of this electrode is detected by closing the welding torch, and then after the other electrode is ground, the wear amount of this electrode is detected by closing the welding torch.

[0020] In some embodiments, the system further includes a welding electrode position detection module, which is used to monitor the distance between the welding electrode and the grinding position in real time through the position coordinates of the welding electrode, or to determine whether the welding electrode is detected by at least one position sensor set on the path, so as to control the grinding device to start after the welding electrode moves into a first set distance before grinding; and / or, to control the grinding device to close after the welding electrode moves out to a second set distance after grinding.

[0021] In some embodiments, the system further includes an electrode grinding condition judgment module, which is used to record the grinding times of the welding electrode and / or the current height of the electrode. If the grinding times of any electrode reach the upper limit value or the current height of any electrode reaches the lower limit value, it is determined that grinding is not allowed; and / or,

[0022] The grinding device further includes a grinding part detection module, which is used to detect whether the grinding part exists or is damaged, so as to determine whether the grinding device meets the grinding operation conditions.

[0023] In some embodiments, the grinding device includes two of the grinding parts, and the grinding part includes a sheet-shaped grinding wheel, which is respectively used to grind the surface of the first electrode and the surface of the second electrode; or,

[0024] The grinding device includes one of the grinding parts, and the grinding part includes a sand belt ring, which is used to grind the surfaces of the first electrode and the second electrode simultaneously or successively.

[0025] In some embodiments, the surface finish detection sensor includes a first fiber optic amplifier and a second fiber optic amplifier, which are arranged back to back, and their surfaces are configured to be parallel to the working surfaces of the first electrode and the second electrode after grinding, so as to detect the surface finish of them respectively.

[0026] In some embodiments, the system further includes an electrode wear degree detection unit, which is used to determine whether the electrode is allowed to be ground by recording the grinding times of the electrode or obtaining the total wear amount by detecting the remaining height of the electrode.

[0027] Another aspect of the present invention provides an automatic grinding method for welding electrodes. The implementation of the automatic grinding method is based on the above-mentioned automatic grinding system, and the method includes the following steps:

[0028] In the case where the welding electrode needs to be ground, it is judged whether the welding electrode is allowed to be ground by combining the grinding times or the total wear amount of the welding electrode. If so, the next step is executed;

[0029] The grinding part detection sensor is used to detect whether the grinding part exists or is damaged, so as to determine whether the grinding device meets the grinding operation conditions. If so, the next step is executed;

[0030] The electrode wear amount is detected by closing the welding torch, and it is compensated to the depth control of the first electrode and the second electrode in this grinding operation;

[0031] The robot is used to control the welding electrode to move to the grinding position. During the movement of the welding electrode, the grinding device is started by the welding electrode position detection module according to the distance between the welding electrode and the grinding position; after the welding electrode reaches the grinding position, the robot is used to control the depth of the welding electrode, and the grinding pressure is controlled in combination with the floating unit to grind the working surfaces of the first electrode and the second electrode in sequence;

[0032] After grinding is completed, the robot is used to control the welding electrode to move to the detection position. The surface finish of the ground electrode working surface is detected by the surface finish detection sensor, and it is judged whether this grinding is qualified through the surface finish; if it is unqualified, the robot is used to control the welding electrode to return to the grinding position to be reground by the grinding device or notify manual processing until the surface finish is qualified;

[0033] After the grinding of a single electrode is completed, the wear amount of the electrode is detected by closing the welding torch in sequence, or the total wear amount is detected after the grinding of two electrodes, and the wear amount of a single electrode is obtained by the dichotomy method, and the wear amount is compensated to the depth control of the first electrode and the second electrode in the welding operation.

[0034] The automatic grinding system and method in the embodiments of the present invention can automate the grinding process, not only reducing the manual operation time, but also significantly improving the overall efficiency of the production line; automatic grinding can avoid the instability of manual grinding, ensure the flatness of the electrode surface after each grinding, improve the electrode contact quality during welding, and further improve the overall quality of body welding; precise control of the grinding amount and maintenance of the surface finish contribute to extending the service life of the electrode, reducing the replacement frequency, and lowering the production cost. The automatic grinding system of the present invention is applicable to Arplas electrodes (such as square electrodes or round electrodes) in the automotive manufacturing industry, especially in automated production lines that require large-scale and high-efficiency welding, and has a wide range of application prospects.

[0035] Additional advantages, objects, and features of the present invention will be partly set forth in the description which follows, and will partly become obvious to those of ordinary skill in the art upon examination of the following, or may be learned by practice of the present invention. The objects and other advantages of the present invention may be realized and obtained by the structure particularly pointed out in the specification and the drawings.

[0036] Those skilled in the art will understand that the objects and advantages that can be achieved by the present invention are not limited to those specifically described above, and the above and other objects that the present invention can achieve will be more clearly understood according to the following detailed description. Brief Description of the Drawings

[0037] The drawings described herein are for further understanding of the present invention, form a part of this application, and do not limit the present invention. The components in the drawings are not drawn to scale, but are only for showing the principles of the present invention. For the convenience of showing and describing some parts of the present invention, the corresponding parts in the drawings may be enlarged, that is, may become larger relative to other components in the exemplary device actually manufactured according to the present invention.

[0038] Figure 1 It is a schematic structural diagram of an automatic grinding system in an embodiment of the present invention.

[0039] Figure 2 It is a schematic structural diagram of a grinding device in an embodiment of the present invention.

[0040] Figure 3 It is a schematic structural diagram of a welding electrode and an electrode surface detection device in an embodiment of the present invention.

[0041] Figure 4 It is a schematic composition diagram of an automatic grinding system in an embodiment of the present invention.

[0042] Figure 5 It is a schematic principle diagram of an automatic grinding system in an embodiment of the present invention.

[0043] Figure 6 It is a flowchart of an automatic grinding method in an embodiment of the present invention.

[0044] Figure 7 It is a flowchart of an automatic grinding method in another embodiment of the present invention.

[0045] Reference Numerals:

[0046] 1. Grinding device; 11. Grinding rotation mechanism; 12. Grinding part; 13. Floating unit; 14. Grinding part detection module; 15. Welding electrode position detection module; 2. Electrode surface detection device; 21. First fiber optic amplifier; 22. Second fiber optic amplifier; 3. Grinding amount control module; 31. Grinding pressure control unit; 32. Grinding time control unit; 33. Grinding part rotation speed control unit; 34. Electrode wear amount detection unit; 4. Communication control box; 61. Welding torch; 62. First electrode; 63. Second electrode. Detailed implementation mode

[0047] To make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in combination with the implementation modes and the drawings. Herein, the illustrative implementation modes of the present invention and their descriptions are used to explain the present invention, but do not limit the present invention.

[0048] Herein, it also needs to be noted that in order to avoid obscuring the present invention due to unnecessary details, only the structures and / or processing steps closely related to the solution of the present invention are shown in the drawings, while other details less related to the present invention are omitted.

[0049] It should be emphasized that the term "including / containing" as used herein refers to the presence of features, elements, steps or components, but does not exclude the presence or addition of one or more other features, elements, steps or components.

[0050] Herein, it also needs to be noted that if not otherwise specified, the term "connection" in this article can not only refer to direct connection, but also represent indirect connection with an intermediate.

[0051] In the following, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same reference numerals represent the same or similar components, or the same or similar steps.

[0052] The present invention aims to provide an automatic grinding system and method for welding electrodes, which can be applied to Arplas electrodes used in the automotive manufacturing industry. The present invention can replace the existing manual grinding method in the island. Through automatic grinding, the present invention aims to reduce the production line downtime and improve production efficiency; at the same time, ensure that zinc chips, oxide layers and other dirt on the electrode surface are removed with the minimum grinding amount, maintain the surface finish of the electrode, thereby improving the quality stability of Arplas welding and extending the service life of the electrode. In addition, the present invention can also avoid the problem of uneven electrode surface caused by manual grinding, and further improve the welding quality and the body appearance quality.

[0053] In the first aspect, as Figures 1-3 shown, the present invention provides an automatic grinding system for welding electrodes, and the welding electrode (such as Figure 3As shown in the figure, the welding gun 61 includes a first electrode 62 and a second electrode 63 installed on the welding gun 61. It can be understood that the first electrode 62 is an upper electrode and can be used as a movable arm electrode; and the second electrode 63 is a lower electrode and can be used as a stationary arm electrode. In other embodiments, both electrodes can be movable arm electrodes, and their movement can be assisted by linear moving structures such as cylinders and screw nut mechanisms. These are conventional solutions in the field and will not be described here. It is sufficient to achieve the welding function.

[0054] Furthermore, the automatic grinding system mainly includes: a grinding device 1 arranged at the grinding position and an electrode surface detection device 2 arranged at the detection position. The grinding device 1 is mainly used to automatically perform the grinding action, and the electrode surface detection device 2 is mainly used to automatically detect whether the electrode surface after grinding is qualified. If it is unqualified, the grinding action can be automatically performed again, or manual intervention can be performed.

[0055] The grinding device 1 includes a grinding rotating mechanism 11 and at least one grinding piece 12 connected to the grinding rotating mechanism 11, and the grinding piece 12 is used to grind the working surface of the first electrode 62 and / or the second electrode 63 to be ground while being driven to rotate by the grinding rotating mechanism 11. The grinding rotating mechanism 11 is responsible for driving the grinding piece 12 to rotate and provide grinding force. The grinding piece 12 drives the working surface of the movable arm electrode or the stationary arm electrode to be ground by rotation, thereby completing the grinding of the electrode. According to the needs, the type of the grinding piece 12 can select suitable abrasives for fine grinding. The working surface mentioned here refers to the surface that is in direct contact with the welding part, that is, the lower surface of the upper electrode and the upper surface of the lower electrode, which is also the surface where zinc scraps, oxide layer and other dirt are mainly attached.

[0056] The electrode surface detection device 2 includes a smoothness detection sensor for detecting the smoothness of the electrode working surface after grinding, so as to judge whether the grinding is qualified by the smoothness. The smoothness detection sensor can ensure that the electrode surface after grinding reaches the expected smoothness. Through the measured value of the smoothness, the system can automatically judge whether the grinding meets the standard, ensuring the quality control of the grinding process.

[0057] In the above embodiments, the present invention can automate the grinding process, which not only reduces the manual operation time but also significantly improves the overall efficiency of the production line; automatic grinding can avoid the instability of manual grinding, ensure the flatness of the electrode surface after each grinding, improve the electrode contact quality during the welding process, and further improve the overall quality of body welding; precise control of the grinding amount and maintenance of the finish contribute to extending the service life of the electrode, reducing the replacement frequency, and lowering the production cost. The automatic grinding system of the present invention is applicable to Arplas electrodes (such as square electrodes or round electrodes) in the automotive manufacturing industry, but is not limited thereto and can also be used for other electrodes, especially in automated production lines that require large-scale and high-efficiency welding, and has broad application prospects.

[0058] In some embodiments, the welding electrode is controlled by a robot to move in the horizontal and vertical directions to perform welding operations and grinding operations. The industrial robot can accurately adjust the position and posture of the electrode to perform different tasks, and can also ensure that the electrode surface is evenly processed during the grinding process, avoiding unstable factors caused by manual operation.

[0059] In some embodiments, the grinding device 1 further includes a floating unit 13 for floatingly mounting the grinding member 12 such that the floating direction is perpendicular to the working surface of the electrode to be ground; this design can ensure that the contact pressure between the grinding member 12 and the electrode surface is uniform and controllable, thereby avoiding damage or unevenness to the electrode surface caused by excessive pressure or uneven pressure. Due to the design of the floating unit 13, it also helps to control the grinding amount of the electrode to the minimum each time, as much as possible to extend the service life of the electrode and reduce costs.

[0060] Furthermore, the floating unit 13 includes an elastic member or a cylinder for combining with the robot to drive the depth of penetration of the electrode to be ground (i.e., the contact depth between the grinding member 12 and the electrode), and maintaining the pressure between the electrode to be ground and the grinding member 12 at a predetermined pressure under the action of the floating unit 13 to ensure the stability and consistency of the grinding process. The elastic member (such as a spring) or the cylinder can adjust the rigidity or flexibility of the floating unit 13 as needed, thereby precisely controlling the contact pressure during grinding.

[0061] As at least one implementable manner, such as Figure 2As shown, the floating unit 13 is in the form of a spring, which can be fixedly installed on the middle fixing plate. A number of springs are installed above and below the middle fixing plate for adjusting the grinding pressure of the upper and lower electrodes; a contact plate can also be set between the spring and the grinding part 12 to ensure its flatness. The pressure that the spring can provide depends on its compression amount. This system can control the depth of the electrode according to requirements, so as to set the pressure to the minimum grinding pressure or a predetermined grinding pressure. For example, a smaller pressure is beneficial to controlling the surface finish of the grinding and helps to reduce the grinding amount (the height or thickness of the removed electrode), while a larger pressure is beneficial to reducing the grinding time and reducing the downtime cost. This system can adjust the grinding pressure according to actual requirements and has wide applicability.

[0062] Through robot control, the application of the floating unit 13, and precise pressure adjustment, the automatic welding electrode grinding system of the present invention can complete the grinding task more efficiently and precisely, ensure the stability of the electrode surface quality, and at the same time reduce the potential errors in manual operation. The system has a high degree of automation and simple operation, can greatly improve the overall efficiency and quality of the welding operation, and has significant advantages especially in large-scale production.

[0063] In some embodiments, as Figure 4 shown, the system further includes a grinding amount control module 3 for controlling the grinding amount of the first electrode 62 and the second electrode 63 by the grinding device 1 in this grinding operation to be the minimum grinding amount or a predetermined grinding amount; the goal of the grinding amount control module 3 is to control the grinding amount of the first electrode 62 and the second electrode 63, precisely control the parameters in the grinding process, and ensure that the influence on the electrode in each grinding operation is controlled within a predetermined range.

[0064] Furthermore, the grinding amount control module 3 includes at least one of a grinding pressure control unit 31, a grinding time control unit 32, and a grinding part rotation speed control unit 33. Of course, all three of these parameters can adjust the grinding amount. In order to reduce the control parameters, one or two of these parameters can be set to be constant, and the grinding amount can be adjusted by adjusting one parameter, simplifying the control method; or all three can be set to be controllable to achieve the best grinding effect. The grinding amount is the thickness or height of the electrode that needs to be removed in one grinding operation. The relationship among the grinding pressure, the grinding time, and the rotation speed of the grinding part 12 (the linear speed of the contact point between the electrode surface and the grinding part 12) is very close. The combined action of these three determines the effect of welding electrode grinding. The most suitable combination can be found through experiments to ensure the best grinding effect and avoid excessive wear on the electrode.

[0065] First, the grinding pressure control unit 31 is configured to control the depth of penetration of the electrode to be ground driven by the robot in combination with the worn amount of the electrode to be ground and the grinding amount of the current grinding operation, so that the pressure between the electrode to be ground and the grinding member 12 is maintained at a predetermined pressure under the action of the floating unit 13. As described above, the pressure between the electrode to be ground and the grinding member 12 is maintained within a predetermined pressure range. This control method utilizes the action of the floating unit 13 to automatically adjust the contact pressure of the electrode according to the set conditions, so as to avoid excessive wear or uneven grinding. Optionally, the grinding process can be controlled as a constant force or a variable force process, such as the grinding pressure is initially the largest and then gradually decreases. This method is beneficial to grind a better finish.

[0066] Second, the grinding time control unit 32 is configured to control the grinding time by controlling the residence time of the electrode to be ground at the grinding position or the start time of the grinding device 1 through the robot; by controlling the grinding time, it can ensure that the electrode is fully ground and avoid over-grinding, thereby improving the grinding efficiency and maintaining the quality of the electrode surface.

[0067] Third, the grinding member rotation speed control unit 33 is communicatively connected to the grinding rotation mechanism 11 to control the rotation speed of the grinding member 12 according to the grinding amount. The grinding amount control module 3 automatically adjusts the rotation speed of the grinding member 12 according to the required grinding amount. A higher rotation speed can be used for faster grinding, while a lower rotation speed can be used for fine grinding to ensure the quality of the grinding process. In addition, a larger grinding pressure and a higher rotation speed may result in more heat generation, which needs to be appropriately controlled to avoid overheating of the electrode or excessive wear of the grinding member 12.

[0068] In the above embodiments, through the cooperation of grinding pressure control, grinding time control, and grinding member 12 rotation speed control, the system can accurately control the grinding amount of each grinding process, ensuring that the surface of the electrode is ideally trimmed. The automation degree of the entire system is high, and it can complete the precise grinding task without manual intervention, improving production efficiency and reducing human errors. Through precise pressure and time control, the uniformity and integrity of the electrode surface can be maintained, and the service life of the electrode can be extended. The grinding amount control module 3 can not only improve the grinding accuracy, but also ensure the high efficiency and consistency of the production process. Through automatic control and parameter adjustment, the system can optimize the electrode grinding process in actual production, reduce unnecessary losses, and improve the welding quality and the service life of the equipment.

[0069] In some embodiments, such as Figure 4As shown, the grinding amount control module 3 further includes an electrode wear amount detection unit 34, which is used to detect the pre-grinding wear amount of the electrode by closing the welding torch 61 before grinding. The wear amount is the difference between the initial height and the current height of the electrode (or the sum of all grinding amounts). The pre-grinding wear amount is used to compensate for the depth control of the first electrode 62 and the second electrode 63 in this grinding operation to obtain the predetermined pressure, and can also maintain the stability of the predetermined pressure during the grinding process. This solution helps to improve the one-time passing rate of the grinding quality, avoid multiple grindings, and control the grinding time.

[0070] Further, the electrode wear amount detection unit 34 is also used to detect the post-grinding wear amount of the electrode by closing the welding torch 61 after grinding. The post-grinding wear amount is used to compensate for the depth control of the first electrode 62 and the second electrode 63 in the welding operation to ensure the stability of the electrode and the welding quality during the welding process.

[0071] In the above embodiment, the difference between the post-grinding wear amount and the pre-grinding wear amount is the predetermined grinding amount of this grinding operation. At least two schemes can be used to calculate the electrode wear amount, such as the dichotomy method or detecting each electrode one by one.

[0072] First, after the total wear amount is detected by closing the welding torch 61 for the post-grinding wear amounts of the first electrode 62 and the second electrode 63, the dichotomy method (i.e., the averaging method, considering the grinding amounts of the two electrodes to be equal) is used for calculation. The wear amounts of the two electrodes satisfy the following relationship:

[0073] Total wear amount = Wear amount of the first electrode + Wear amount of the second electrode

[0074] In this method, it is assumed that the wear amounts of the two electrodes are the same. Therefore, by measuring the grinding amount or wear amount of one electrode, the wear amount of the other electrode can be inferred. This method averages the wear amounts of the two electrodes and uses this as the correction value for the depth amount. This solution is relatively simple to implement, does not require measuring the wear conditions of each electrode separately, and the calculation is relatively efficient.

[0075] Second, after one electrode is ground and before the other electrode is ground, the wear amount of this electrode is detected by closing the welding torch 61, and then after the other electrode is ground, the wear amount of this electrode is detected by closing the welding torch 61. In this method, the wear amount of each electrode is detected separately. The specific operation is to measure the wear amount of one electrode by closing the welding torch 61 after grinding one electrode, and then grind the other electrode and detect the wear amount of this electrode. The relationship between the current height or the remaining height of each electrode and the grinding amount satisfies:

[0076] Electrode current height = Electrode height before the previous grinding - Grinding amount

[0077] This method precisely calculates and accumulates the wear amount of each electrode through separate recording of each electrode. This method can accurately record the wear condition of each electrode, avoid the errors that may be brought by the averaging method, and ensure the accuracy of the penetration depth control more effectively. It is especially suitable for welding operations that require high precision.

[0078] Through the above two methods, selection can be made according to actual requirements and precision requirements. If high-precision penetration depth control is required, detecting the wear amount of each electrode one by one will be more suitable; if time and efficiency are crucial, the binary method can provide a more convenient solution. It can be understood that the electrode wear amount detection step can be mainly executed by means of some structures of the robot and the welding torch 61 without additional hardware structure.

[0079] In some embodiments, such as Figure 4 shown, the system further includes a welding electrode position detection module 15, which is used to monitor the distance between the welding electrode and the grinding position in real time through the position coordinates of the welding electrode or whether at least one position sensor set at a specific position on the path detects the welding electrode, so as to control the start of the grinding device 1 after the welding electrode moves into a first set distance before grinding; and / or, to control the shutdown of the grinding device 1 after the welding electrode moves out of a second set distance after grinding is completed.

[0080] In the above embodiments, at least two schemes can be adopted to control the opening and closing of the grinding device 1, that is, real-time monitoring through the position coordinates of the welding electrode and detection through the position sensor. In Embodiment 1, the system can directly obtain the coordinates of the welding electrode and calculate the distance between the welding electrode and the grinding position according to these coordinates. In Embodiment 2, the system can install at least one position sensor (such as a laser sensor, an acoustic wave sensor, etc.) at specific positions on the path. Of course, position sensors can also be set on the path from the welding position to the grinding position and the path from the grinding position to the detection position to detect in real time whether a welding electrode passes through. After the sensor detects the welding electrode, it will trigger the corresponding control operation of the system. These control methods can effectively ensure the accuracy and automation of the grinding process, reduce manual intervention, improve efficiency, reduce the running time of the grinding part 12, reduce energy consumption and reduce the running loss of the grinding part 12.

[0081] In some embodiments, such as Figure 4As shown, the system further includes an electrode grinding condition judgment module, which is used to record the grinding times of the welding electrode and / or the current height of the electrode. If the grinding times of any electrode reach the upper limit value or the current height of any electrode reaches the lower limit value, it is determined that grinding is not allowed. After the welding electrode is ground multiple times, its performance and lifespan may be affected. Therefore, once the grinding times reach the upper limit, the system will determine that further grinding is not allowed. If the height of the electrode is lower than the set lower limit value, it indicates that the electrode may have been excessively worn or damaged, and grinding cannot restore its performance, so grinding also needs to be stopped. When any of the above conditions is met, that is, the grinding times reach the upper limit value or the current height of the electrode reaches the lower limit value, the system will determine that the electrode grinding operation is not allowed to continue, and a new welding electrode needs to be replaced in a timely manner. This judgment can effectively avoid the risks brought by excessive grinding and ensure the safety of electrode use and welding quality.

[0082] In some embodiments, as Figure 4 shown, the grinding device 1 further includes a grinding part detection module 14, which is used to detect whether the grinding part 12 exists or is damaged, so as to determine whether the grinding device 1 meets the grinding operation conditions. In addition to detecting the existence of the grinding part 12, the module also checks whether the grinding part 12 is damaged. For example, the grinding part 12 may be damaged due to long-term use or excessive wear, which will affect the grinding effect. The detection module confirms whether the grinding part 12 is damaged through sensors or other detection methods. When the grinding part 12 does not exist or is damaged, the system will determine that the grinding device 1 does not meet the grinding operation conditions, thereby preventing the grinding operation from continuing and avoiding the decline in grinding quality or equipment damage caused by problems with the grinding part 12. This function can ensure the safety and effect of the grinding operation and improve the reliability of the system.

[0083] Furthermore, the grinding part detection module 14 can be implemented in various structures, and the specific selection depends on the system requirements, precision requirements, and the characteristics of the grinding part 12. The available methods include, but are not limited to, optical sensors, proximity sensors, vision detection systems, and RFID (Radio Frequency Identification), etc. An optical sensor (such as an infrared sensor, a laser sensor, etc.) is used to detect whether the grinding part 12 exists or is damaged. For example, when the grinding part 12 is missing, the light beam is interrupted, and the sensor can detect the change in the signal, thereby determining whether the grinding part 12 exists; this method has the advantages of high precision and non-contact measurement, and is suitable for detections that require high sensitivity. The proximity sensor determines the state of the grinding part 12 by detecting its presence or surface changes; for example, an inductive sensor can sense the presence of a metal grinding part 12, while a capacitive sensor is suitable for non-metal grinding parts 12; this method has the advantages of non-contact measurement, fast response, and being applicable to various materials of the grinding part 12. The vision detection system detects the state of the grinding part 12 through a camera and image processing algorithms, such as by photographing the surface of the grinding part 12 and using image recognition algorithms to determine its damage or wear condition; this method has the advantages of high precision and can directly identify the shape, defects, etc. of the grinding part 12, and is suitable for complex situations.

[0084] In some embodiments, the grinding device 1 includes two of the grinding parts 12, and the grinding part 12 includes a sheet-shaped grinding wheel, which is respectively used for grinding the surface of the first electrode 62 and the surface of the second electrode 63. The sheet-shaped grinding wheel can be installed on structures such as a cylinder. In this solution, each electrode surface can be processed independently, thereby ensuring the accuracy and controllability of the grinding effect. For the grinding requirements of different electrode surface characteristics, a suitable grinding wheel can be selected for customization.

[0085] In some other embodiments, as Figure 1 and Figure 2 shown, the grinding device 1 includes one of the grinding parts 12, and the grinding part 12 includes a sand belt loop, which is used for grinding the surfaces of the first electrode 62 and the second electrode 63 simultaneously or successively. The sand belt loop has a large contact area and a high grinding efficiency, and is suitable for processing larger electrode surfaces. Due to its continuous structure, a uniform frictional force can be provided during the grinding process, which helps to improve the grinding efficiency. The combined structure of the sand belt loop and the floating unit 13 helps to reduce the usage structure, simplify the control method, and reduce costs. Optionally, longitudinal and lateral elastic limits can also be added at the installation location of the sand belt loop floating unit 13 to ensure the flatness of the electrode after grinding.

[0086] Optionally, the grinding rotation mechanism 11 may include a motor for driving the rotation of the grinding member 12; if the grinding member 12 is in the form of a sand belt loop, the grinding rotation mechanism 11 may further include two pulleys for mounting the sand belt loop, one of the pulleys being directly or indirectly connected to the motor and serving as the driving pulley. The grinding member rotation speed control unit 33 may be disposed in the lower communication control box 4, such as using a single-chip microcomputer or a PLC. The interaction module, control center, etc. of the grinding device 1 of this system may all be disposed in the communication control box 4.

[0087] In some embodiments, as Figure 3 shown, the surface finish detection sensor includes a first fiber optic amplifier 21 and a second fiber optic amplifier 22, which are arranged back to back, can form a symmetric structure, and their surfaces are configured to be parallel to the ground working surfaces of the first electrode 62 and the second electrode 63 to respectively perform surface finish detection on them. In this embodiment, the surfaces of the fiber optic amplifiers are configured to be parallel to the ground working surfaces of the electrodes, ensuring that the surface finish of the electrode surfaces can be detected at a suitable angle. Through this parallel arrangement, the fiber optic amplifiers can provide more accurate surface finish measurement data because the contact angle between the optical fibers and the electrode surfaces does not interfere with the accuracy of reflection or optical sensing. Through the fiber optic amplifiers, the sensor can detect minute flaws, roughness, or surface finish changes on the electrode surfaces through the reflection or scattering characteristics of light. Precise surface finish data can help adjust the quality of the electrode surface grinding to ensure that the performance of the electrodes meets the requirements.

[0088] In addition to using the surface finish detection sensor, other solutions may also be adopted for the electrode surface detection device 2, such as white light interferometry, surface profilometry, etc. White light interferometry uses a white light interferometer and utilizes the interference phenomenon of white light to detect the surface microtopography, thereby judging the surface finish. By irradiating the surface with white light, minute topographical differences on the surface will cause phase changes in the light waves. When the phase difference of the reflected light waves reaches a certain value, light wave interference occurs, thereby forming interference fringes. By analyzing the morphology of the interference fringes, the roughness and surface finish of the surface can be inferred. Surface profilometry uses a profilometer or an optical microscope to calculate the surface finish by scanning the surface profile and detecting its microstructure. A probe or a laser scanning device is used to scan the surface to collect the height information of each point on the surface, forming a surface profile map. The surface finish is judged by the smoothness of the surface topography. The higher the surface finish, the smoother the surface and the smaller the change in the surface profile.

[0089] In some embodiments, the system further includes an electrode wear degree detection unit, which is used to determine whether the electrode is allowed to be ground by recording the number of electrode grinding times or obtaining the total wear amount by detecting the remaining height of the electrode. The electrode wear degree detection unit tracks the wear condition of the electrode in real time by recording the grinding times or monitoring the remaining height, ensuring that the electrode can be stopped from grinding or replaced in time before the wear reaches the limit, thereby ensuring the safety of the grinding process and the usage efficiency of the electrode. This can not only improve production efficiency but also extend the service life of the equipment.

[0090] In a second aspect, the present invention provides an automatic grinding method for a welding electrode. The implementation of the automatic grinding method is based on the above automatic grinding system. As Figures 5-7 shown, the method includes the following steps:

[0091] 1. Determine whether grinding is allowed: When the welding electrode needs to be ground, determine whether the welding electrode is allowed to be ground by combining the number of grinding times or the total wear amount of the welding electrode. If so, proceed to the next step.

[0092] 2. Detection of the grinding part 12: Detect whether the grinding part 12 exists or is damaged through the grinding part 12 detection sensor to determine whether the grinding device 1 meets the grinding operation conditions. If so, proceed to the next step; only when the grinding part 12 is normal and meets the conditions can the grinding operation continue. This step can ensure the normal operation of the grinding device 1.

[0093] 3. Detection and compensation of electrode wear amount: Detect the electrode wear amount through the closing of the welding torch 61 and compensate it to the depth control of the first electrode 62 and the second electrode 63 in this grinding operation; according to the electrode wear condition, accurately adjust the grinding depth to ensure that each grinding can be compensated to an appropriate degree.

[0094] 4. Movement of the welding electrode to the grinding position and control of the grinding process: Control the movement of the welding electrode to the grinding position through the robot. During the movement of the welding electrode, the grinding device 1 is controlled to start according to the distance between the welding electrode and the grinding position by the welding electrode position detection module 15; after the welding electrode reaches the grinding position, control the depth of the welding electrode through the robot, and combine with the floating unit 13 to control the grinding pressure, and grind the working surfaces of the first electrode 62 and the second electrode 63 in sequence.

[0095] 5. Detection of the surface finish after grinding: After grinding is completed, control the movement of the welding electrode to the detection position through the robot, detect the surface finish of the working surface of the electrode after grinding through the surface finish detection sensor, and determine whether this grinding is qualified through the surface finish; if not, control the welding electrode to return to the grinding position by the robot to be ground again by the grinding device 1 or notify manual intervention for processing until the surface finish is qualified and the grinding is completed.

[0096] In the above embodiments, whether the welding electrode needs to be ground can be determined by the number of welding workpieces of the electrode or the working duration. When the welding electrode welds on multiple workpieces, after a certain number of welding workpieces are completed, the surface of the electrode will gradually wear. By counting the number of welding workpieces of the electrode, when the welding reaches a predetermined number of times, it can be determined that the electrode needs to be ground. Another way is to judge whether grinding is needed by the working duration of the electrode. As the use time of the electrode increases, the wear on the surface of the electrode will also accumulate. When the working duration reaches a certain limit, the working effect of the electrode will deteriorate, so grinding is required. A reasonable standard can be set for this number of times or duration according to the electrode material and specific usage conditions.

[0097] Compared with the existing manual grinding, in the automatic grinding system and method of the welding electrode in the embodiment of the present invention, the flatness of the surface of the electrode after each grinding is improved, thereby prolonging the service life of the electrode and ensuring the connection quality of Arplas welding. Secondly, by adopting a floating grinding structure to ensure the minimum grinding amount, the service life of the electrode is extended again.

[0098] After the electrode is automatically ground, there is no need for people to enter the automatic production line island for cleaning, which means that the automatic production line does not need to stop, reducing the daily production time by about one hour and reducing the labor intensity of workers.

[0099] After the present invention adopts the electrode wear detection and compensation scheme, it can ensure that each electrode can reach the correct grinding position every time, and will not cause the electrode to be unable to accurately reach the grinding position and incomplete grinding due to the electrode wear caused by grinding, ensuring the first-pass rate of electrode grinding; through the wear detection and compensation scheme, it can ensure the distance between the electrode and the plate part (workpiece) again, ensuring the welding quality.

[0100] The automatic grinding system and method of the welding electrode in the embodiment of the present invention combines the precise control of multiple parameters such as grinding pressure, grinding time, and the rotation speed of the grinding part 12, and can automatically grind the welding electrode efficiently and precisely. In industrial production lines that require high-frequency and high-precision welding, such as the fields of automobile manufacturing, shipbuilding, and steel structure welding. The automatic grinding system in the embodiment of the present invention can ensure that the welding electrode continuously maintains stable performance after long-term work, thereby ensuring the welding quality and production efficiency. The automatic control can reduce manual intervention, reduce the influence of human factors, ensure that each welding electrode is evenly ground, and ensure the continuous and stable operation of the production line.

[0101] The automatic grinding system in the embodiment of the present invention can also be used in welding environments that require high consistency and precision, such as aerospace, nuclear power plant construction and precision manufacturing. The applicable scenarios of the automatic grinding system and method are mainly concentrated in fields with high requirements for welding quality, production efficiency and cost. Through the automated grinding process, manual intervention can be reduced, grinding accuracy can be improved, electrode service life can be extended, production costs can be optimized, and the stability of welding quality can be ensured. These advantages make the automatic grinding system have important application value in modern production lines, precision manufacturing and high-demand welding fields.

[0102] Corresponding to the above method, the present invention also provides an apparatus, which includes a computer device, the computer device includes a processor and a memory, the memory stores computer instructions, the processor is used to execute the computer instructions stored in the memory, and when the computer instructions are executed by the processor, the apparatus / system implements the steps of the method described above.

[0103] The embodiment of the present invention also provides a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, the steps of the automatic grinding method of the welding electrode are implemented. The computer-readable storage medium can be a tangible storage medium, such as a random access memory (RAM), a memory, a read-only memory (ROM), an electrically programmable ROM, an electrically erasable programmable ROM, a register, a floppy disk, a hard disk, a removable storage disk, a CD-ROM, or any other form of storage medium known in the technical field.

[0104] It should be understood by those skilled in the art that the exemplary components, systems and methods described in conjunction with the embodiments disclosed herein can be implemented in hardware, software or a combination of the two. Whether it is performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention. When implemented in hardware, it can be, for example, an electronic circuit, an application-specific integrated circuit (ASIC), appropriate firmware, a plug-in, a function card, etc. When implemented in software, the elements of the present invention are programs or code segments used to perform the required tasks. The program or code segment can be stored in a machine-readable medium, or transmitted on a transmission medium or a communication link via a data signal carried in a carrier.

[0105] It should be clear that the present invention is not limited to the specific configurations and processes described above and shown in the figures. For the sake of brevity, detailed descriptions of known methods are omitted here. In the above embodiments, several specific steps are described and shown as examples. However, the method process of the present invention is not limited to the specific steps described and shown. Those skilled in the art can make various changes, modifications, and additions, or change the order between steps after understanding the spirit of the present invention.

[0106] In the present invention, features described and / or illustrated for one embodiment can be used in the same or a similar manner in one or more other embodiments, and / or combined with the features of other embodiments or replace the features of other embodiments.

[0107] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, various changes and modifications can be made to the embodiments of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An automatic grinding system for a welding electrode, the welding electrode comprising a first electrode (62) and a second electrode (63) mounted on a welding gun (61), characterized in that: The system comprises: a grinding device (1) arranged at a grinding position and an electrode surface detection device (2) arranged at a detection position; The grinding device (1) comprises a grinding rotating mechanism (11) and at least one grinding piece (12) connected to the grinding rotating mechanism (11), wherein the grinding piece (12) is used to grind the working surface of the first electrode (62) and / or the second electrode (63) to be ground while being driven to rotate by the grinding rotating mechanism (11); the grinding device (1) further comprises a floating unit (13) for floatingly mounting the grinding piece (12) so that its floating direction is perpendicular to the working surface of the electrode to be ground; the floating unit (13) comprises an elastic member or a cylinder, which is used to maintain the pressure between the electrode to be ground and the grinding piece (12) at a predetermined pressure under the action of the floating unit (13) in combination with the depth of the electrode to be ground driven by the robot; The system further comprises a grinding amount control module (3) for controlling the grinding amount of the grinding device (1) on the first electrode (62) and the second electrode (63) to be maintained at a minimum grinding amount or a predetermined grinding amount during the current grinding operation; the grinding amount control module (3) comprises at least one of a grinding pressure control unit (31), a grinding time control unit (32) and a grinding piece rotation speed control unit (33); The grinding amount control module (3) further comprises an electrode wear amount detection unit (34) for detecting the amount of wear of the electrode before grinding by closing the welding gun (61) before grinding, wherein the amount of wear is the difference between the initial height and the current height of the electrode, and the amount of wear before grinding is used to compensate for the depth control of the first electrode (62) and the second electrode (63) in the current grinding operation to obtain the predetermined pressure; The electrode surface detection device (2) comprises a smoothness detection sensor for detecting the smoothness of the electrode working surface after grinding, so as to judge whether the grinding is qualified according to the smoothness; if it is unqualified, the robot controls the welding electrode to return to the grinding position and be ground again by the grinding device (1) or notify manual processing until the smoothness is qualified.

2. The automatic grinding system for welding electrodes according to claim 1, characterized in that: The welding electrode is controlled by a robot to move in horizontal and vertical directions to perform welding and grinding operations.

3. The automatic grinding system for welding electrodes according to claim 2, characterized in that: The grinding pressure control unit (31) is used to control the depth of the electrode to be ground driven by the robot in combination with the wear amount of the electrode to be ground and the grinding amount of the current grinding operation, so that the pressure between the electrode to be ground and the grinding piece (12) is maintained at a predetermined pressure under the action of the floating unit (13); The grinding time control unit (32) is used to control the grinding time by controlling the residence time of the electrode to be ground at the grinding position or the start time of the grinding device (1) through the robot; The grinding piece rotation speed control unit (33) is communicatively connected to the grinding rotation mechanism (11) to control the rotation speed of the grinding piece (12) according to the grinding amount.

4. The automatic grinding system for welding electrodes according to claim 3, characterized in that: The electrode wear detection unit (34) is also used to detect the wear amount of the electrode after grinding by closing the welding gun (61) after grinding is completed, and the wear amount after grinding is used to compensate for the depth control of the first electrode (62) and the second electrode (63) during the welding operation; The difference between the wear amount after grinding and the wear amount before grinding is the predetermined grinding amount for this grinding operation; The wear amount of the first electrode (62) and the second electrode (63) after grinding is obtained by using a binary method to calculate the total wear amount after the welding gun (61) is closed; or, after grinding of one electrode is completed and before grinding of the other electrode, the wear amount of the electrode is detected by closing the welding gun (61), and then after grinding of the other electrode is completed, the wear amount of the electrode is detected by closing the welding gun (61).

5. The automatic grinding system for welding electrodes according to claim 1, characterized in that: The system further comprises a welding electrode position detection module (15) for monitoring the distance between the welding electrode and the grinding position in real time through the position coordinates of the welding electrode or by detecting the welding electrode through at least one position sensor set in the path, so as to control the grinding device (1) to start after the welding electrode moves to a first set distance before grinding; and / or to control the grinding device (1) to shut down after the welding electrode moves to a second set distance after grinding is completed.

6. The automatic grinding system for welding electrodes according to claim 1, characterized in that: The system further comprises an electrode grinding condition judgment module, which is used to record the number of grinding times of the welding electrode and / or the current height of the electrode. If the number of grinding times of any electrode reaches an upper limit or the current height of any electrode reaches a lower limit, it is determined that grinding is not allowed; and / or, The grinding device (1) further comprises a grinding piece detection module (14) for detecting whether the grinding piece (12) exists or is damaged, so as to determine whether the grinding device (1) meets grinding operation conditions.

7. The automatic grinding system for welding electrodes according to claim 1 or 2, characterized in that: The grinding device (1) comprises two grinding members (12), wherein the grinding members (12) comprise sheet-shaped grinding wheels, and are used to grind the surface of the first electrode (62) and the surface of the second electrode (63), respectively; or, The grinding device (1) comprises a grinding piece (12), wherein the grinding piece (12) comprises a sanding belt ring and is used to grind the surfaces of the first electrode (62) and the second electrode (63) simultaneously or successively.

8. The automatic grinding system for welding electrodes according to claim 1, characterized in that: The surface finish detection sensor comprises a first optical fiber amplifier (21) and a second optical fiber amplifier (22), which are arranged back to back and have surfaces configured to be parallel to the polished working surfaces of the first electrode (62) and the second electrode (63) so as to perform surface finish detection on them respectively.

9. The automatic grinding system for welding electrodes according to claim 2, characterized in that: The system also includes an electrode wear degree detection unit, which is used to determine whether the electrode is allowed to be ground by recording the number of times the electrode is ground, or by detecting the remaining height of the electrode to obtain the total wear amount.

10. An automatic grinding method for welding electrodes, characterized in that: The automatic grinding method is implemented based on the automatic grinding system according to any one of claims 1 to 9, and the method comprises the following steps: In the case where the welding electrode needs to be sharpened, judging whether the welding electrode is allowed to be sharpened in combination with the number of sharpening times or the total wear amount of the welding electrode, and if so, executing the next step; Using a grinding part (12) detection sensor to detect whether the grinding part (12) exists or is damaged, so as to determine whether the grinding device (1) meets the grinding operation conditions, and if so, executing the next step; The amount of electrode wear is detected by closing the welding gun (61), and the wear is compensated to control the depth of the first electrode (62) and the second electrode (63) in the current grinding operation; The robot controls the welding electrode to move to the grinding position, and during the movement of the welding electrode, the welding electrode position detection module (15) controls the grinding device (1) to start according to the distance between the welding electrode and the grinding position; after the welding electrode reaches the grinding position, the robot controls the depth of the welding electrode, and the grinding pressure is controlled in combination with the floating unit (13), so as to grind the working surfaces of the first electrode (62) and the second electrode (63) in sequence; After the grinding is completed, the robot controls the welding electrode to move to the inspection position, and the surface finish of the electrode working surface after grinding is detected by the surface finish detection sensor, and whether the grinding is qualified is determined by the surface finish; if it is unqualified, the robot controls the welding electrode to return to the grinding position and be ground again by the grinding device (1) or notify manual processing until the surface finish is qualified; After a single electrode is ground, the wear amount of the electrode is detected in sequence by closing the welding gun (61), or after two electrodes are ground, the total wear amount is detected, and the wear amount of the single electrode is obtained by binary division, and the wear amount is compensated to control the depth of the first electrode (62) and the second electrode (63) of the welding operation.

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