A welding device for manufacturing the walking beam of a beam pumping unit

Abstract

The present invention relates to the technical field of manufacturing donkey heads for oil pumping units, and specifically to a welding device for manufacturing donkey heads for walking beam oil pumping units, comprising a workbench and welding robots arranged on both sides of the workbench; an angle adjustment component, the angle adjustment component being arranged in the middle of the top surface of the workbench, a positioning box being arranged on the angle adjustment component, the angle adjustment component being used to adjust the placement angle of the positioning box; a clamping component, the clamping component being arranged above the positioning box, a donkey head body to be welded being placed on the clamping component, the clamping component being used to clamp and fix the donkey head body; an adaptive vibration module for assisting welding is also provided inside the clamping component. Compared to the prior art, the present application provides a receiving layer in conjunction with an adaptive vibration module, so that the system can achieve precise vibration control of 0.5‑2μm during welding, and has the mechanical strength required for a large-amplitude impact of 20μm in the cleaning stage, thereby improving the overall welding quality.

Description

Technical Field

[0001] The present invention relates to the technical field of the manufacturing of the walking beam pumping unit pony head, and in particular to a welding device for manufacturing the walking beam pumping unit pony head. Background Art

[0002] The pony head is one of the important components of the walking beam pumping unit. Its main function is to connect the walking beam and the sucker rod and bear periodic loads during the pumping process. Therefore, the welding quality of the pony head directly affects the operation stability and service life of the pumping unit. During the production and manufacturing process of the pony head, multiple steel plates are usually spliced and formed by welding, and then subsequent machining and assembly are carried out.

[0003] In the prior art, in a welding tooling for a pumping unit pony head in a Chinese patent document with the publication number CN206445443U, it is proposed that both side plates are positioned by side plate positioning columns, so the positions of the two side plates relative to the upper surface of the platform are determined; because the relative position between the rotating shaft of the compass and the platform is fixed, and the radius of the compass is equal to the radius of the arc plate, the arc formed by the free end of the compass on the side plate is the positioning position of the arc plate on the side plate. The arc plate can be correctly positioned according to the arc drawn by the compass. During the assembly process of the pony head, because the side plates are horizontally arranged and the arc plate is directly placed on the side plates, there is no need to suspend the side plates and the arc plate, thus reducing the operation complexity and the risk coefficient. However, similar to the traditional method, traditional devices usually use fixed fixtures to clamp workpieces and lack self-adaptive adjustment functions. As a result, when replacing pony head bodies of different specifications, it is necessary to manually replace the fixtures or carry out cumbersome adjustments, increasing the clamping time and affecting the production efficiency. At the same time, most traditional clamping mechanisms adopt a single rigid clamping method. During the welding process, the workpiece may be displaced or deformed due to welding stress and high-temperature thermal deformation, affecting the welding accuracy. Secondly, traditional welding devices lack an active vibration assistance function. During the welding process, the fluidity of the molten pool metal is poor, and defects such as pores and slag inclusions are likely to occur, affecting the weld quality. At the same time, due to the absence of a vibration disturbance mechanism, the heat distribution in the molten pool during the welding process is uneven, resulting in local overheating or uneven cooling, thereby affecting the mechanical properties of the weld. In addition, the welding slag generated during welding usually relies on manual knocking or brushing for cleaning, with low cleaning efficiency and easy damage to the surface of the workpiece, affecting the final product quality. Therefore, the present application discloses a welding device for manufacturing the walking beam pumping unit pony head. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a welding device for manufacturing the walking beam pumping unit pony head, so as to solve the problems that the traditional welding device has a single clamping method and lacks self-adaptive adjustment, resulting in cumbersome clamping, the welding accuracy being affected by thermal deformation, and at the same time lacking an active vibration assistance function, making the fluidity of the molten pool poor, easy to generate defects, the cleaning of welding slag relying on manual labor and having low efficiency, and affecting the welding quality and production efficiency.

[0005] Based on the above purpose, the present invention provides a welding device for manufacturing a beam pumping unit head, comprising a workbench and welding robots arranged on both sides of the workbench;

[0006] An angle adjustment component, the angle adjustment component is arranged in the middle of the top surface of the workbench, a positioning box is provided on the angle adjustment component, and the angle adjustment component is used to adjust the placement angle of the positioning box;

[0007] A clamping assembly is provided above the positioning box, a donkey head body to be welded is placed on the clamping assembly, and the clamping assembly is used to clamp and fix the donkey head body;

[0008] An adaptive vibration module for assisting welding is also provided inside the clamping assembly. The adaptive vibration module is used to assist the welding of the welding robot and to assist in cleaning the welding slag after welding the donkey head body.

[0009] Preferably, the angle adjustment assembly includes a rotating shaft rotatably mounted in the middle of the top surface of the workbench, two connecting plates are respectively sleeved on one side of the rotating shaft, and a threaded sleeve is commonly provided between the bottoms of the two connecting plates. A positioning frame is also provided on one side of the workbench, a screw rod is rotatably mounted on the positioning frame, the screw rod is threadedly connected to the threaded sleeve, and a rotating handle is fixedly mounted on one end of the screw rod.

[0010] Preferably, the positioning box is fixedly mounted on one side of the outer surface of the rotating shaft.

[0011] Preferably, the clamping assembly includes two fixed boxes fixedly mounted on the upper surface of the positioning box, two mounting plates are slidably mounted in the middle of the fixed boxes, a sliding groove is provided in the middle of the top surfaces of the two fixed boxes, and a dovetail slider adapted to the sliding groove is provided at the bottom of the two mounting plates. A first positioning seat is also provided above the middle of the fixed box, and first rotating screws are rotatably mounted on both sides of the first positioning seat, and the two first rotating screws are respectively threadedly connected to the two mounting plates. When the first rotating screw is rotated, the mounting plate moves horizontally along the sliding groove, and positioning plates are provided on the top surfaces of the two mounting plates, and two relatively arranged clamping blocks are provided on the top surfaces of the two positioning plates, and the two clamping blocks are used to perform preliminary limit clamping on the donkey head body.

[0012] Preferably, a group of second positioning seats are provided on both sides of the top surface of the fixed box, and two groups of second positioning seats are set as two, and a second rotating screw is installed on the two second positioning seats to rotate together, and a moving block is threadedly connected to one side of the second rotating screw, and a tooth plate is fixedly connected to the top surface of the moving block, and a tooth plate is rotatably installed on one side of the positioning plate, and a gear meshing with the tooth plate is fixedly connected to one side of the tooth plate, and a clamping sleeve is provided on the outer surface of the tooth plate away from the gear, and the two clamping sleeves are used to reinforce and clamp the donkey head body.

[0013] Preferably, the clamping sleeve is eccentrically arranged and is made of rubber material.

[0014] Preferably, the clamping blocks are arranged obliquely, and the two clamping blocks on one of the fixing boxes are arranged obliquely relative to each other, and the clamping sleeves on the two fixing boxes are arranged in opposite directions.

[0015] Preferably, the clamping block includes a receiving layer and a contact layer from bottom to top, the top surface of the contact layer is provided with a plurality of contact grooves in contact with the donkey head body, the contact layer is set to rubber material, and the receiving layer is set to 17-4PH precipitation hardened stainless steel.

[0016] Preferably, the adaptive vibration module includes several piezoelectric ceramic sheets arranged inside the supporting layer, and the several piezoelectric ceramic sheets adopt a d³³-d³¹ composite mode. By changing the electrode division method, a single ceramic sheet can simultaneously support: high-frequency vibration in the thickness direction and low-frequency vibration in the radial direction, and the high-frequency vibration frequency in the thickness direction is set to 50-80kHz; the low-frequency vibration frequency in the radial direction is set to 180-220Hz.

[0017] Preferably, the control method of the adaptive vibration module comprises the following steps:

[0018] a. Use the current sensor to detect the working status of the welding robot in real time. When the welding current is ≥10A, it is determined that the welding operation is in progress and the high-frequency micro-amplitude vibration mode is activated;

[0019] b. In the high-frequency micro-amplitude vibration mode, the piezoelectric ceramic piece is controlled to vibrate at a frequency of 50-80 kHz and an amplitude of 2-5 μm, and the vibration direction is at an angle of ±45° to the movement direction of the welding robot's welding gun;

[0020] c. Use an infrared temperature sensor to monitor the temperature of the weld area in real time. When the temperature gradient ΔT ≥ 150°C / cm, dynamically increase the driving voltage of the piezoelectric ceramic to 150-200V and reduce the vibration frequency to below 50kHz.

[0021] d. When the welding current is continuously less than 1A for more than 5 seconds, switch to low-frequency, high-amplitude cleaning mode, control the piezoelectric ceramic to vibrate at a frequency of 180-220Hz and an amplitude of 15-20μm, and superimpose a 0.1-0.5Hz sweep frequency signal;

[0022] e. During the welding slag cleaning process, the vibration energy transfer efficiency is fed back through the acceleration sensor. If the efficiency is less than 75%, the phase reversal control is triggered to make the vibration waveform phase difference jump 180 degrees to break the welding slag adhesion.

[0023] Beneficial effects of the present invention:

[0024] 1. This type of welding device for manufacturing the donkey head of a walking beam pumping unit is equipped with a clamping assembly and a two-stage clamping mechanism to achieve high-precision and stable fixation of the donkey head body: the first stage uses an inclined clamping block driven by a screw to achieve rapid adaptive positioning. Its inclined surface structure ensures a close fit with the surface of the special-shaped workpiece and can adapt to the clamping and fixation of donkey heads of different specifications; the second stage applies a progressive clamping force through the gear rack transmission system of the eccentric rubber sleeve. The rubber material not only protects the workpiece surface but also enhances the friction coefficient. The reverse symmetrical layout design balances the clamping forces on both sides, effectively offsetting the effects of welding vibration and thermal deformation, meeting the requirements of heavy-load welding while avoiding workpiece deformation.

[0025] 2. This welding device for manufacturing beam pumping unit heads features a supporting layer and an adaptive vibration module. This module, combined with a 17-4PH precipitation-hardened stainless steel supporting layer, achieves a balance between vibration energy transfer and structural strength. High-frequency vibration (50-80kHz) is efficiently conducted through the supporting layer, creating precisely controllable micro-disturbance during the welding process. This increases the fluidity of the molten metal by over 40% and significantly reduces porosity and slag inclusion defects. Low-frequency vibration (180-220Hz) leverages the material's ultra-high strength to achieve stable, large-amplitude output, ensuring thorough slag removal. The supporting layer's excellent thermal conductivity (18.4W / m·K) quickly disperses welding heat, preventing overheating and failure of the piezoelectric ceramic. Its thermal expansion compatibility with the ceramic ensures interface stability under long-term thermal cycling. This enables the system to achieve precise vibration control at the 0.5-2μm level during welding while maintaining the mechanical strength required for large-amplitude impacts of 20μm during the cleaning phase, improving overall welding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only for the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0027] Figure 1 This is a schematic diagram of the three-dimensional structure of the present invention from a first viewing angle;

[0028] Figure 2 This is a schematic diagram of the three-dimensional structure of the present invention from a second viewing angle;

[0029] Figure 3 This is a schematic diagram of the planar structure of the present invention;

[0030] Figure 4 For the present invention Figure 2 A in the middle is an enlarged structural diagram;

[0031] Figure 5 This is a schematic diagram of the structure of the clamping assembly of the present invention;

[0032] Figure 6 This is a schematic diagram of the structure of a partial clamping assembly and an adaptive vibration module of the present invention;

[0033] Figure 7 This is a schematic diagram of the partial structure of the clamping assembly of the present invention;

[0034] Figure 8 For the present invention Figure 7 The enlarged structural diagram at B in the middle;

[0035] Figure 9 This is a schematic diagram of the structure of the clamping block after receiving the present invention;

[0036] Figure 10 It is a schematic diagram of the planar structure of the clamping block and the adaptive vibration module of the present invention.

[0037] The following are marked in the figure:

[0038] 1. Workbench; 2. Welding robot; 3. Rotating shaft; 4. Positioning box; 5. Positioning frame; 6. Screw; 7. Connecting plate; 8. Rotating handle; 9. Fixing box; 10. Sliding groove; 11. Mounting plate; 12. Dovetail slider; 13. First positioning seat; 14. First rotating screw; 15. Positioning plate; 16. Clamping block; 17. Second positioning seat; 18. Second rotating screw; 19. Moving block; 20. Tooth plate; 21. Rotating rod; 22. Gear; 23. Clamping sleeve; 24. Contact layer; 25. Supporting layer; 26. Contact tooth groove; 27. Piezoelectric ceramic sheet; 28. Donkey head body. DETAILED DESCRIPTION

[0039] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to specific embodiments.

[0040] It should be noted that, unless otherwise defined, the technical terms or scientific terms used in the present invention should have the ordinary meanings understood by those with ordinary skills in the field to which the present invention belongs. The "first", "second" and similar terms used in the present invention do not denote any order, quantity or importance, but are only used to distinguish different components. Words such as "including" or "comprising" mean that the elements or objects appearing before this word cover the elements or objects listed after this word and their equivalents, without excluding other elements or objects. Words such as "connected" or "coupled" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Upper", "lower", "left", "right", etc. are only used to represent relative position relationships, and when the absolute position of the object being described changes, the relative position relationship may also change accordingly.

[0041] As Figures 1 to 10 shown, the welding device for manufacturing the walking beam pumping unit horsehead includes a workbench 1 and welding robots 2 arranged on both sides of the workbench 1; an angle adjustment assembly, which is arranged in the middle of the top surface of the workbench 1, and a positioning box 4 is arranged on the angle adjustment assembly, and the angle adjustment assembly is used to adjust the placement angle of the positioning box 4; a clamping assembly, which is arranged above the positioning box 4, and the horsehead body 28 to be welded is placed on the clamping assembly, and the clamping assembly is used to clamp and fix the horsehead body 28; an adaptive vibration module for assisting welding is also arranged inside the clamping assembly, and the adaptive vibration module is used to assist the welding of the welding robot 2 and assist in cleaning the welding slag after the welding of the horsehead body 28.

[0042] After the equipment is started, the operator places the horsehead body 28 on the clamping assembly, and the clamping assembly automatically adjusts to fix the workpiece. The angle adjustment assembly adjusts the angle of the positioning box 4 according to the welding process requirements, so that the horsehead body 28 is in a suitable welding position. The welding robot 2 starts to operate and performs precise welding on the programmed trajectory. During the welding process, the adaptive vibration module makes fine-tuning vibrations according to the welding progress to ensure uniform welds and reduce welding spatter. After the welding is completed, the vibration module continues to act to promote the shedding of excess welding slag and reduce the need for manual cleaning. Finally, the welded horsehead body 28 is taken off, the equipment is reset, and preparations are made for the next welding task. The angle adjustment assembly can flexibly adjust the placement angle of the positioning box 4, so that the horsehead body 28 can be in the most suitable angle for welding, ensuring the weld quality, improving the welding accuracy, and reducing welding defects caused by poor angles. The clamping assembly firmly fixes the horsehead body 28, avoids affecting the welding quality due to the movement or shaking of the workpiece during welding, improves the overall stability, and ensures the consistency of welding.

[0043] As Figure 1As shown, the angle adjustment assembly includes a rotating shaft 3 rotatably mounted in the middle of the top surface of the workbench 1, two connecting plates 7 are respectively sleeved on one side of the rotating shaft 3, and a threaded sleeve is commonly provided between the bottoms of the two connecting plates 7. A positioning frame 5 is also provided on one side of the workbench 1. A screw rod 6 is rotatably mounted on the positioning frame 5. The screw rod 6 is threadedly connected to the threaded sleeve. A rotating handle 8 is fixedly mounted on one end of the screw rod 6. The positioning box 4 is fixedly mounted on one side of the outer surface of the rotating shaft 3;

[0044] The operator places the donkey head body 28 in the clamping assembly and preliminarily aligns the welding position. According to the welding process requirements, the operator can manually turn the handle 8 to drive the screw 6 to rotate. The screw 6 drives the connecting plate 7 and the rotating shaft 3 to rotate through the threaded connection relationship with the threaded sleeve, so that the angle of the positioning box 4 changes until the donkey head body 28 reaches the ideal welding angle. After the adjustment is completed, the structure of the connecting plate 7 and the positioning frame 5 ensures that the positioning box 4 is stable and motionless at the set angle, and the welding robot 2 performs automatic welding according to the set trajectory.

[0045] like Figures 2 to 10 As shown, the clamping assembly includes two fixed boxes 9 fixedly mounted on the upper surface of the positioning box 4, and two mounting plates 11 are slidably mounted in the middle of the fixed box 9. A sliding groove 10 is provided in the middle of the top surface of the two fixed boxes 9, and a dovetail slider 12 adapted to the sliding groove 10 is provided at the bottom of the two mounting plates 11. A first positioning seat 13 is also provided above the middle of the fixed box 9, and first rotating screws 14 are rotatably mounted on both sides of the first positioning seat 13. The two first rotating screws 14 are respectively threadedly connected to the two mounting plates 11. When the first rotating screws 14 are rotated, the mounting plates 11 move horizontally along the sliding groove 10, and positioning plates 15 are provided on the top surfaces of the two mounting plates 11. Two relatively arranged clamping blocks 16 are provided on the top surfaces of the two positioning plates 15. The two clamping blocks 16 are used to perform preliminary limit clamping on the donkey head body 28. The clamping blocks 16 are inclined, and the two clamping blocks 16 located on one of the fixed boxes 9 are relatively inclined.

[0046] The operator first rotates the first rotating screw 14 to move the two clamping blocks 16 closer to or farther away from each other to match the donkey head bodies 28 of different sizes. Then, the operator continues to rotate the first rotating screw 14 to gradually move the two clamping blocks 16 closer to each other to preliminarily clamp the donkey head body 28 to ensure that it is in a stable state. Since the clamping blocks 16 are inclined, they can better fit the surface of the donkey head body 28, further enhancing the limiting effect and preventing the workpiece from being displaced during the welding process. The mounting plate 11 is driven to move along the sliding groove 10 by the first rotating screw 14, so that the clamping blocks 16 can adapt to donkey head bodies 28 of different sizes, thereby achieving rapid adjustment, improving the adaptability of the equipment, and reducing the adjustment time when the workpiece is replaced.

[0047] A group of second positioning seats 17 are provided on both sides of the top surface of the fixed box 9, and two groups of second positioning seats 17 are provided. A second rotating screw 18 is installed on the two second positioning seats 17 in common rotation. One side of the second rotating screw 18 is threadedly connected to a moving block 19. The top surface of the moving block 19 is fixedly connected to a gear plate 20. A gear plate 20 is rotatably installed on one side of the positioning plate 15. One side of the gear plate 20 is fixedly connected to a gear 22 meshing with the gear plate 20. The outer surface of the gear plate 20 away from the gear 22 is provided with a clamping sleeve 23. The two clamping sleeves 23 are used to reinforce and clamp the donkey head body 28. The clamping sleeve 23 is eccentrically arranged and is made of rubber. The clamping sleeves 23 on the two fixed boxes 9 are arranged in opposite directions.

[0048] After the initial fixation, the operator rotates the second rotating screw 18, driving the moving block 19 to move along the screw direction, causing the tooth plate 20 to be displaced, and the meshing action of the gear 22 and the tooth plate 20 synchronously adjusts the position of the clamping sleeve 23. Since the clamping sleeve 23 adopts an eccentric design, a uniform clamping force is gradually applied to the donkey head body 28 during the movement to complete the reinforced clamping. The rubber clamping sleeve 23 reduces direct pressure on the workpiece while ensuring stability, preventing damage to the surface of the donkey head body 28. A two-stage clamping mechanism is adopted. The first step is to perform preliminary limiting by the clamping block 16, and the second step is to reinforce the clamping of the donkey head body 28 by the clamping sleeve 23. This method ensures the stability of the donkey head body 28 during welding, avoids displacement caused by vibration or welding thermal deformation, and improves welding accuracy. The clamping sleeves 23 on the two fixed boxes 9 are set in opposite directions. This symmetrical layout can offset the imbalance of the unilateral clamping force, make the clamping more stable, and further improve the seismic resistance and stability of the workpiece during welding.

[0049] like Figure 9 、 Figure 10 As shown, the clamping block 16 includes a receiving layer 25 and a contact layer 24 from bottom to top. The top surface of the contact layer 24 is provided with a plurality of contact grooves 26 that contact the donkey head body 28. The contact layer 24 is set to a rubber material, and the receiving layer 25 is set to 17-4PH precipitation hardened stainless steel.

[0050] The top surface of the contact layer 24 is provided with a contact tooth groove 26, which can increase the friction between the donkey head body 28 and the clamping block 16 to prevent the workpiece from sliding or deflecting during the clamping process. This design ensures that the donkey head body 28 will not be displaced by external force or vibration during welding, thereby improving the welding accuracy. After the contact layer 24 contacts the donkey head body 28, the donkey head body 28 presses the contact layer 24, driving one side of the contact layer 24 to be concave inward (such as Figure 9As shown, the contact layer 24 wraps one side of the donkey head body 28. The bearing layer 25 is made of -PH precipitation hardening stainless steel, which has high strength, high hardness and excellent wear resistance. It can provide sufficient structural support to prevent the clamping block 16 from deforming or wearing due to long-term use. This material can withstand a large clamping force and has a long service life, reducing the equipment maintenance cost. By adopting the layering of the contact layer 24 and the bearing layer 25, the rigidity and flexibility are taken into account. It can not only ensure the stability of the clamping block 16, but also provide a good buffering effect. This structure can remain stable in a high-intensity welding environment and extend the service life of the clamping system.

[0051] The adaptive vibration module includes a number of piezoelectric ceramic sheets 27 arranged inside the bearing layer 25. The number of piezoelectric ceramic sheets 27 adopts the d³³-d³¹ composite mode. By changing the electrode segmentation method, a single ceramic sheet can support both high-frequency vibration in the thickness direction and low-frequency vibration in the radial direction at the same time. The high-frequency vibration frequency in the thickness direction is set to 50 - 80 kHz; the low-frequency vibration frequency in the radial direction is set to 180 - 220 Hz.

[0052] The control method of the adaptive vibration module includes the following steps:

[0053] a. Real-time detect the working state of the welding robot 2 through a current sensor. When the welding current ≥ 10 A, it is determined that welding operation is in progress, and the high-frequency micro-amplitude vibration mode is activated.

[0054] b. In the high-frequency micro-amplitude vibration mode, control the piezoelectric ceramic sheet 27 to vibrate at a frequency of 50 - 80 kHz and an amplitude of 2 - 5 μm, and the vibration direction forms an angle of ±45° with the moving direction of the welding torch of the welding robot.

[0055] c. Real-time monitor the temperature of the weld area through an infrared temperature sensor. When the temperature gradient ΔT ≥ 150 °C / cm, dynamically increase the driving voltage of the piezoelectric ceramic sheet to 150 - 200 V and reduce the vibration frequency to below 50 kHz.

[0056] d. When the welding current continuously < 1 A for more than 5 seconds, switch to the low-frequency high-amplitude cleaning mode, control the piezoelectric ceramic sheet 27 to vibrate at a frequency of 180 - 220 Hz and an amplitude of 15 - 20 μm, and superimpose a 0.1 - 0.5 Hz sweep signal.

[0057] e. During the welding slag cleaning process, feedback the vibration energy transfer efficiency through an acceleration sensor. If the efficiency < 75%, trigger the phase inversion control to make the phase difference of the vibration waveform jump 180° to break the attachment of the welding slag.

[0058] This adaptive vibration module achieves intelligent vibration control by integrating a specially designed piezoelectric ceramic sheet component inside the receiving layer 25. Its core lies in the piezoelectric ceramic sheet 27 adopting the d³³-d³¹ composite mode. Through electrode segmentation technology, a single ceramic element can simultaneously generate two different types of vibrations: high-frequency vibration (50 - 80 kHz) in the thickness direction for assisting the welding process, and low-frequency vibration (180 - 220 Hz) in the radial direction for post-weld cleaning. The system automatically switches the working mode by real-time monitoring of the welding current. When the detected welding current ≥ 10 A, the high-frequency micro-amplitude vibration mode is activated. At this time, the piezoelectric ceramic sheet acts in a direction at a 45° angle to the moving direction of the welding torch with precise high-frequency small-amplitude vibration (2 - 5 μm) to optimize the molten pool metal flow. When the infrared temperature sensor detects that the temperature gradient in the weld area exceeds 150 °C / cm, the system dynamically adjusts the driving voltage to 150 - 200 V and reduces the frequency to below 50 kHz to cope with the high-temperature working condition. After welding, if the current continuously remains below 1 A for 5 seconds, it automatically switches to the low-frequency high-amplitude cleaning mode. At this time, the piezoelectric ceramic sheet vibrates more powerfully (15 - 20 μm) in cooperation with a swept-frequency signal of 0.1 - 0.5 Hz to effectively shake off the welding slag. During this process, if the acceleration sensor detects that the vibration transfer efficiency is less than 75%, the system immediately triggers a jump control with a 180° phase inversion to enhance the welding slag peeling effect using the inertial impact effect. The entire control process achieves seamless connection between welding assistance and welding slag cleaning, and ensures the optimal vibration assistance effect in different process stages by intelligently adjusting the vibration parameters;

[0059] In the context of using 17-4PH precipitation-hardening stainless steel for the receiving layer 25, the vibration conduction mechanism of the piezoelectric ceramic sheet 27 will be significantly optimized. In specific implementation, the piezoelectric ceramic sheet 27 forms a metallurgical bond with the receiving layer 25 through a vacuum brazing process. The nickel-based transition layer (thickness 50 - 80 μm) at the interface not only ensures the efficient coupling of vibration energy (transfer efficiency > 92%), but also provides the necessary electrical insulation performance. When the system activates the high-frequency micro-amplitude vibration mode, the 17-4PH material receiving layer 25 will amplify the thickness-direction vibration of the piezoelectric ceramic sheet in the form of a standing wave, forming a microscopic displacement of 0.5 - 2 μm on the workpiece surface. This precise mechanical perturbation can reduce the surface tension of the molten pool by about 40%. After switching to the low-frequency high-amplitude cleaning mode, the high yield strength (≥ 1170 MPa) of the material can withstand the alternating stress brought by a 20-μm amplitude, and its precipitation-hardening phase (Cu-rich precipitation phase) can also effectively inhibit the grain boundary slip caused by vibration, ensuring the structural integrity of the device under long-term vibration load.

Claims

1. A welding device for manufacturing the walking beam of a beam pumping unit, characterized in that, include: A workbench (1) and welding robots (2) arranged on both sides of the workbench (1); An angle adjustment component, the angle adjustment component is arranged in the middle of the top surface of the workbench (1), a positioning box (4) is arranged on the angle adjustment component, and the angle adjustment component is used to adjust the placement angle of the positioning box (4); A clamping assembly, the clamping assembly is arranged above the positioning box (4), a donkey head body (28) to be welded is placed on the clamping assembly, and the clamping assembly is used to clamp and fix the donkey head body (28); An adaptive vibration module for assisting welding is also provided inside the clamping assembly, and the adaptive vibration module is used to assist the welding of the welding robot (2) and to assist in cleaning the welding slag after welding the donkey head body (28); The clamping assembly comprises two fixed boxes (9) fixedly mounted on the upper surface of the positioning box (4), two mounting plates (11) are slidably mounted in the middle of the fixed boxes (9), the top surfaces of the two mounting plates (11) are provided with positioning plates (15), the top surfaces of the two positioning plates (15) are provided with two relatively arranged clamping blocks (16), and the two clamping blocks (16) are used to perform preliminary limiting clamping on the donkey head body (28); the clamping blocks (16) comprise a receiving layer (25) and a contact layer (24) from bottom to top, the contact layer (24) is set to a rubber material, and the receiving layer (25) is set to a 17-4PH precipitation hardened stainless steel; The adaptive vibration module includes a plurality of piezoelectric ceramic sheets (27) arranged inside the receiving layer (25), wherein the plurality of piezoelectric ceramic sheets (27) adopt a d³³-d³¹ composite mode, and by changing the electrode segmentation method, a single ceramic sheet can simultaneously support: high-frequency vibration in the thickness direction and low-frequency vibration in the radial direction, wherein the high-frequency vibration frequency in the thickness direction is set to 50-80 kHz; and the low-frequency vibration frequency in the radial direction is set to 180-220 Hz; The control method of the adaptive vibration module comprises the following steps: a. Using a current sensor to detect the working state of the welding robot (2) in real time, when the welding current is ≥10A, it is determined that the welding operation is in progress, and the high-frequency micro-amplitude vibration mode is activated; b. In the high-frequency micro-amplitude vibration mode, the piezoelectric ceramic piece (27) is controlled to vibrate at a frequency of 50-80 kHz and an amplitude of 2-5 μm, and the vibration direction is at an angle of ±45° to the moving direction of the welding robot welding gun; c. Using an infrared temperature sensor to monitor the temperature of the weld area in real time, when the temperature gradient ΔT ≥ 150°C / cm, dynamically increase the driving voltage of the piezoelectric ceramic piece (27) to 150-200V and reduce the vibration frequency to below 50kHz; d. When the welding current is continuously less than 1A for more than 5 seconds, switch to the low-frequency high-amplitude cleaning mode, control the piezoelectric ceramic piece (27) to vibrate at a frequency of 180-220 Hz and an amplitude of 15-20 μm, and superimpose a 0.1-0.5 Hz sweep frequency signal; e. During the welding slag cleaning process, the vibration energy transfer efficiency is fed back through the acceleration sensor. If the efficiency is less than 75%, the phase reversal control is triggered to make the vibration waveform phase difference jump 180 degrees to break the welding slag adhesion.

2. The welding device for manufacturing the walking beam pumping unit horsehead according to claim 1, characterized in that, The angle adjustment assembly comprises a rotating shaft (3) rotatably mounted in the middle of the top surface of the workbench (1), two connecting plates (7) are respectively sleeved on one side of the rotating shaft (3), and a threaded sleeve is commonly provided between the bottoms of the two connecting plates (7), and a positioning frame (5) is further provided on one side of the workbench (1), a screw rod (6) is rotatably mounted on the positioning frame (5), the screw rod (6) is threadedly connected to the threaded sleeve, and a rotating handle (8) is fixedly mounted on one end of the screw rod (6).

3. The welding device for manufacturing the walking beam pumping unit horsehead according to claim 2, characterized in that, The positioning box (4) is fixedly mounted on one side of the outer surface of the rotating shaft (3).

4. The welding device for manufacturing the walking beam pumping unit pony head according to claim 3, wherein, A sliding groove (10) is provided in the middle of the top surface of the two fixed boxes (9), and a dovetail slider (12) adapted to the sliding groove (10) is provided at the bottom of the two mounting plates (11). A first positioning seat (13) is also provided above the middle of the fixed box (9), and first rotating screws (14) are rotatably installed on both sides of the first positioning seat (13). The two first rotating screws (14) are respectively threadedly connected to the two mounting plates (11). When the first rotating screws (14) are rotated, the mounting plate (11) moves horizontally along the sliding groove (10). A group of second positioning seats (17) are provided on both sides of the top surface of the fixed box (9). The two groups of second positioning seats (17) are provided on both sides of the top surface of the fixed box (9). The second positioning seats (17) are each provided with two, and a second rotating screw (18) is rotatably mounted on each of the two second positioning seats (17), and a moving block (19) is threadedly connected to one side of the second rotating screw (18), and a toothed plate (20) is fixedly connected to the top surface of the moving block (19), and a rotating rod (21) is rotatably mounted on one side of the positioning plate (15), and a gear (22) meshing with the toothed plate (20) is fixedly connected to one side of the rotating rod (21), and a clamping sleeve (23) is sleeved on the outer surface of the rotating rod (21) away from the gear (22), and the two clamping sleeves (23) are used to reinforce and clamp the donkey head body (28).

5. The welding device for manufacturing the walking beam pumping unit pony head according to claim 4, wherein, The clamping sleeve (23) is eccentrically arranged, and the clamping sleeve (23) is made of rubber material.

6. The welding device for manufacturing the walking beam pumping unit horsehead according to claim 5, characterized in that, The clamping block (16) is arranged at an angle, and the two clamping blocks (16) located on one of the fixed boxes (9) are arranged at an angle relative to each other, and the clamping sleeves (23) on the two fixed boxes (9) are arranged in opposite directions.

7. The welding device for manufacturing the walking beam pumping unit pony head according to claim 1, characterized in that, The top surface of the contact layer (24) is provided with a plurality of contact tooth grooves (26) that are in contact with the donkey head body (28).

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