Automatic welding system for large-span cable bridge

Abstract

The invention discloses an automatic welding system for a large-span cable bridge, and relates to the technical field of electric arc welding. An automatic welding system for a large-span cable bridge comprises a frame mechanism, the frame mechanism comprises a bottom frame, and a welding assembly is arranged on the bottom frame; the welding assembly comprises a mechanical arm and a welding head assembly; the welding head assembly comprises a welding box mechanism, the welding box mechanism comprises a welding flux box, a top hole is formed in the upper wall of the welding flux box in a penetrating mode, and a bottom hole is formed in the lower wall of the welding flux box in a penetrating mode; one end of the upper wall of the welding flux box fixedly communicates with a connecting pipe, a hopper is fixedly inserted into the connecting pipe, and welding flux is loaded in the hopper; the output end of the mechanical arm is fixedly connected with the welding flux box; a contact tube mechanism is arranged at the upper part of the welding box mechanism; according to the automatic welding system for the large-span cable bridge, a welding flux flows through the bottom hole to make contact with the cable bridge, and when a welding wire is fused to weld the cable bridge, the welding flux wraps the cable bridge, so that the welding safety is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of arc welding, and particularly to an automatic welding system for large-span cable trays. Background Art

[0002] A rigid structure system composed of straight sections, elbows, tees, crosses of trough type, tray type or ladder type, as well as brackets (arm type supports), hangers, etc., which closely supports cables, is called a cable tray (referred to as a tray for short).

[0003] Cable trays are divided into trough type, tray type, ladder type, grid type and other structures, and are composed of brackets, brackets and installation accessories, etc. The trays in buildings can be erected independently or attached to various buildings (structures) and pipe gallery brackets, and all parts need to be galvanized.

[0004] Large-span cable trays are assembled from pultruded fiberglass profiles and are suitable for power cables, control cables, lighting cables and accessories, etc. Compared with iron trays, they have the advantages of long service life, convenient installation, low cost, easy cutting and no need for maintenance.

[0005] Welding systems for cable trays are usually special welding equipment used to connect and fix cable trays. Such devices can include: arc welders, welding jigs and automatic welding machines, etc. These devices and equipment can help ensure the welding quality and structural stability of cable trays.

[0006] The patent with the publication number CN118951232B discloses a welding device for cable trays, which includes a welding table. The bottom of the welding table is fixedly installed with table legs, the top of the welding table is fixedly installed with a welding frame, the top of the welding frame is fixedly installed with a lifting device. The lifting device includes a lifting motor, a threaded rod and a sleeve. The lifting motor is fixedly installed on the top of the welding frame, the threaded rod is fixedly installed at the output end of the lifting motor, the sleeve is slidably installed on the circumferential surface of the threaded rod, the threaded rod is threadedly connected with the sleeve, the circumferential surface of the sleeve is fixedly installed with a welding gun, a slow-speed conveying device is arranged on the top of the welding table, a clamping device is arranged on the welding table, and a collecting device is arranged on the top of the welding table.

[0007] In the above technical solution, a welding gun is directly used for welding. During the welding process, the high-temperature welding wire is in direct contact with the air and is easy to react with oxygen and nitrogen to form oxides and nitrides. These brittle phases will significantly reduce the mechanical properties of the weld, such as strength, toughness and corrosion resistance, and even cause cracks. Therefore, it has an impact on the welding quality of cable trays. There is an urgent need for an automatic welding system for large-span cable trays to solve the above existing problems. Summary of the Invention

[0008] The object of the present invention is to provide an automatic welding system for large-span cable trays to solve the problems raised in the above-mentioned background technology.

[0009] To achieve the above object, the present invention provides the following technical solution: An automatic welding system for large-span cable trays, including a frame mechanism. The frame mechanism includes a bottom frame, on which a positioning component for docking cable trays is provided, and a welding component corresponding to the positioning component is provided on the bottom frame; The welding component includes a robotic arm fixedly connected to the bottom frame and a welding head component; The welding head component includes a welding box mechanism. The welding box mechanism includes a hollow flux box. A top hole is penetrated through the middle of the upper wall of the flux box, and a bottom hole corresponding to the top hole is penetrated through the middle of the lower wall of the flux box; One end of the upper wall of the flux box is fixedly communicated with a connecting pipe. The end of the connecting pipe is fixedly inserted with a funnel-shaped hopper. The lower port of the hopper is inserted into the flux box. A hopper cover is fixedly clamped on the upper port of the hopper, and the hopper is loaded with flux; The output end of the robotic arm is fixedly connected to the flux box; A conductive nozzle mechanism is arranged above the welding box mechanism; A conveying mechanism is arranged above the conductive nozzle mechanism.

[0010] As a preferred technical solution of the present invention, the positioning component includes a fixed seat fixedly embedded in the bottom frame. The fixed seat is U-shaped, and annular ring rails are fixedly embedded at both ends of the fixed seat; Each ring rail is movably installed with a ring frame component; The ring frame component includes an annular ring block. The ring block is coaxial with the ring rail and sleeved in the ring rail. The middle of the outer wall of the ring of the ring frame is fixedly sleeved with a ring block adapted to be inserted into the ring rail.

[0011] The lower side of the inner wall of the ring of the ring frame is fixedly connected with a bottom attaching wall. One side of the inner wall of the ring of the ring frame is fixedly connected with a side attaching wall perpendicular to the bottom attaching wall. The side attaching wall and the bottom attaching wall are fixedly connected, and the ends of the bottom attaching wall and the side attaching wall both extend out of the ring frame; A clamping component opposite to the bottom attaching wall is arranged on the upper side of the inner wall of the ring of the ring frame. The clamping component includes an electric telescopic column fixedly embedded in the ring frame. The output end of the electric telescopic column is fixedly connected with a pedestal, and a conveyor belt is fixedly connected to the lower side of the pedestal.

[0012] As a preferred technical solution of the present invention, a door control component is arranged in the middle of the lower wall of the flux box; The door control component includes a door plate groove opened at the middle side of the bottom hole and communicated with the bottom hole; Two door panels are adaptively inserted into the door panel groove, and the two door panels are stacked. A through hole is formed through the middle of the surface of each door panel. One end of each of the two door panels, which is away from each other, is fixedly connected with a resilient plate. The end of the resilient plate, which is away from the door panel, is bent and extends out of the lower wall of the flux cask. A counterweight bar is fixedly connected to the end of the resilient plate.

[0013] The nozzle mechanism includes a nozzle fixedly connected to the flux cask. One end of the nozzle corresponds to the top hole and is fixedly connected with a guide ring. The other end of the nozzle is fixedly connected with a wire.

[0014] The conveying mechanism includes a hollow conveying box. An inlet hole is formed through the middle of the upper wall of the conveying box, and an outlet hole is formed through the middle of the lower wall of the conveying box. A welding wire is inserted through the inlet hole and the outlet hole of the conveying box. The upper end of the guide ring is fixedly connected to the conveying box and communicates with the outlet hole. The welding wire is inserted into the flux cask through the guide ring and the nozzle. The welding wire is adapted to the top hole and the bottom hole, and the welding wire is adapted to the through hole.

[0015] On one side of the inside of the conveying box and close to the outlet hole, a first driving wheel mechanism is symmetrically arranged. Each first driving wheel mechanism includes a fixing plate fixedly connected to the conveying box. A motor is fixedly connected to one side of the fixing plate. The output end of the motor is fixedly connected with a first pulley. The fixed end of the motor is fixedly connected with a first shaft column. The first shaft column is movably sleeved with an arm through a torsion spring. One end of the arm, which is away from the first shaft column, is movably connected with a second shaft column through a bearing. The end of the second shaft column, which is away from the arm, is fixedly connected with a driving wheel corresponding to the motor. A first friction strip is fixedly connected to the outside of the driving wheel at equal intervals and uniformly. The end of the driving wheel, which is away from the second shaft column, is fixedly connected with a second pulley. The second pulley and the first pulley are jointly sleeved with a belt. The driving wheels of the two first driving wheel mechanisms are attached to the welding wire from both sides.

[0016] On one side of the inside of the conveying box and close to the inlet hole, a second driving wheel mechanism is symmetrically arranged. Each second driving wheel mechanism includes an adjusting cylinder fixedly connected to the conveying box. The output end of the adjusting cylinder is fixedly connected with a U-shaped wheel seat. Sliding grooves are respectively formed through the two side wall surfaces of the wheel seat. A sensing component is arranged inside each sliding groove. The sensing component includes a strip column vertically inserted into the sliding groove. Springs are fixedly wound around both ends of the strip column and are located inside the sliding groove. The wheel seat is clamped with a wheel axle adapted to be inserted into the sliding groove. The middle part of the wheel axle is movably sleeved with a driven wheel through a bearing. The outer side of the driven wheel is fixedly connected with second friction strips at equal intervals and evenly. The driven wheels of the two second driving wheel mechanisms are attached to the welding wire from both sides; The strip column penetrates through the wheel axle, and the spring is attached to the wheel axle.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) An automatic welding system for a large-span cable bridge. Through the extrusion of the resilient plate, the two door panels are pushed closer along the door panel grooves, so that the through holes formed on the surfaces of the two door panels are aligned and communicate with the bottom holes formed on the bottom wall of the flux box. The flux flows through the bottom holes and contacts the cable bridge. When the welding wire melts and welds the cable bridge, it is wrapped by the flux, improving the welding safety.

[0018] (2) An automatic welding system for a large-span cable bridge. By synchronously pulling the two side door panels by the resilient plate, the bottom holes formed on the bottom wall of the flux box are completely closed, preventing the flux from leaking during the movement of the welding head assembly from the source, avoiding polluting the working environment and wasting the flux, and saving costs.

[0019] (3) An automatic welding system for a large-span cable bridge. The elastic deformation characteristic of the resilient plate can buffer the inertial impact during the movement of the robotic arm, avoiding the jamming or deformation of the door panels caused by rigid connection. At the same time, it allows the two side door panels to move independently within a certain range, adapting to the attitude changes of the welding head assembly during complex trajectory movement, especially suitable for welding scenarios with multi-station switching or long-distance movement, ensuring the sealing reliability of the welding box mechanism when the robotic arm drives the welding head assembly to adjust the position state.

[0020] (4) An automatic welding system for a large-span cable bridge. The surface of the driving wheel is fixedly connected with first friction strips at equal intervals and evenly, increasing the contact area between the driving wheel and the welding wire and reducing the wire slipping rate. The second driving wheel mechanism pre-adjusts the initial spacing of the driven wheels through an adjusting cylinder to match welding wires of different diameters; the elastic floating connection between the driven wheel and the wheel seat enables the driven wheel to slide along the sliding groove in real time according to the tension change, avoiding wire scratching or jamming caused by rigid contact and improving the stability of wire feeding.

[0021] (5) An automatic welding system for a large-span cable bridge. The sensing component collects the sliding displacement of the driven wheel in real time and linearly converts it into a real-time tension value. When the tension deviates from the set range, the control system automatically adjusts the air pressure of the adjusting cylinder to dynamically correct the spacing between the two driven wheels, reducing the tension fluctuation, ensuring the wire feeding stability of the welding wire, and improving the dynamic tension adaptive adjustment ability of wire feeding.

[0022] (6)An automatic welding system for a large-span cable tray. When the robotic arm drives the welding head assembly to perform large-angle flipping, such as in the overhead welding position or during high-speed movement, the driven wheel can slide along the chute, adapting to the bending of the wire path, compensating for changes in inertial force and friction through sliding, avoiding wire feeding jams in complex postures, improving wire feeding stability, reducing weld formation deviation, and enhancing the quality of automatic welding.

[0023] (7)An automatic welding system for a large-span cable tray. By monitoring the wire tension through the sensing assembly and limiting the conveying tension of the wire, a drawing and straightening force is formed when the first driving wheel mechanism and the second driving wheel mechanism convey the wire, applying a reverse bending moment to the bent wire, and cooperating with the first friction strip on the surface of the driving wheel and the second friction strip on the surface of the driven wheel to improve the straightness of the wire, especially having a significant rectifying effect on the initial bending of the coiled wire.

[0024] (8)An automatic welding system for a large-span cable tray. The first driving wheel mechanism and the second driving wheel mechanism respectively form support fulcrums at the outlet hole and the inlet hole in the conveying box. Cooperating with the guiding ring of the nozzle mechanism between the conveying box and the flux box, the coaxiality of the wire is controlled within a certain range, ensuring that a uniform coating layer is formed when the wire passes through the flux at a constant speed, avoiding the problem of flux accumulation caused by skewing, and improving the uniformity of the flux-coated wire.

[0025] (9)An automatic welding system for a large-span cable tray. Aiming at the problem of the wire sagging due to its own weight during large-span conveying, the second driving wheel mechanism automatically increases the supporting force through tension feedback to maintain the straightness of the wire, providing a basis for the arc stability during subsequent welding, thereby enhancing the quality of arc welding.

[0026] (10)An automatic welding system for a large-span cable tray. The cable trays on both sides are opposite to each other at the middle position under the pressing of the clamping assembly and the pushing of the conveyor belt. Then, the robotic arm drives the welding head assembly to push the cable tray from the outside, and through the cooperation with the side wall attachment, the cable trays on both sides can be aligned and fitted, improving the accuracy of butt joint before welding.

[0027] (11)An automatic welding system for a large-span cable tray. By driving the ring frame assembly to flip along the bottom hole, the flux box can be prevented from being inverted. If the required welding precision is not high, the flux box can also be flipped by flipping the robotic arm, so as to directly weld the weld on the lower wall of the cable tray, adapting to the welding precision to adjust the welding method and improving the flexibility of use. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a schematic structural diagram of the present invention; Figure 2 is a schematic diagram of the frame mechanism of the present invention; Figure 3 Schematic diagram of the bottom frame of the present invention; Figure 4 Schematic diagram of the connection of the ring frame assembly of the present invention; Figure 5 Schematic diagram of the ring frame assembly of the present invention; Figure 6 Schematic diagram of the welding assembly of the present invention; Figure 7 Schematic diagram of the welding head assembly of the present invention; Figure 8 Schematic diagram of the solder box mechanism of the present invention; Figure 9 Schematic diagram of the access control component of the present invention; Figure 10 Schematic diagram of the contact tip mechanism of the present invention; Figure 11 Schematic diagram of the conveying mechanism of the present invention; Figure 12 Schematic diagram of the first driving wheel mechanism of the present invention; Figure 13 Schematic diagram of the second driving wheel mechanism of the present invention.

[0029] In the figure: 1. Frame mechanism; 101. Bottom frame; 102. Fixed seat; 103. Ring track; 104. Ring frame; 105. Ring block; 106. Bottom attaching wall; 107. Side attaching wall; 108. Electric telescopic column; 109. Belt seat; 110. Conveyor belt; 2. Manipulator; 3. Solder box mechanism; 301. Flux box; 302. Top hole; 303. Bottom hole; 304. Connecting pipe; 305. Hopper; 306. Hopper cover; 307. Flux; 308. Door panel slot; 309. Door panel; 310. Through hole; 311. Tough plate; 312. Counterweight bar; 4. Contact tip mechanism; 401. Contact tip; 402. Electric wire; 403. Guide ring; 5. Conveying mechanism; 501. Conveying box; 502. Inlet hole; 503. Outlet hole; 504. Welding wire; 6. First driving wheel mechanism; 601. Fixed plate; 602. Motor; 603. First pulley; 604. First shaft column; 605. Connecting arm; 606. Second shaft column; 607. Driving wheel; 608. First friction strip; 609. Second pulley; 610. Belt; 7. Second driving wheel mechanism; 701. Adjusting cylinder; 702. Wheel seat; 703. Chute; 704. Strip column; 705. Spring; 706. Wheel shaft; 707. Driven wheel; 708. Second friction strip. Detailed implementation manners

[0030] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0031] Embodiment: Please refer to Figure 1 , Figure 2 , Figure 6 , Figure 7 , Figure 8 , an automatic welding system for a large-span cable tray, including a frame mechanism 1. The frame mechanism 1 includes a bottom frame 101. A positioning component for docking the cable tray is arranged on the bottom frame 101, and a welding component corresponding to the positioning component is arranged on the bottom frame 101; The welding component includes a robotic arm 2 fixedly connected to the bottom frame 101 and a welding head component; The welding head component includes a welding box mechanism 3. The welding box mechanism 3 includes a hollow welding flux box 301. A top hole 302 is penetrated through the middle of the upper wall of the welding flux box 301, and a bottom hole 303 corresponding to the top hole 302 is penetrated through the middle of the lower wall of the welding flux box 301; One end of the upper wall of the welding flux box 301 is fixedly communicated with a connecting pipe 304. A funnel-shaped hopper 305 is fixedly inserted at the end of the connecting pipe 304. The lower port of the hopper 305 is inserted into the welding flux box 301. A hopper cover 306 is fixedly clamped at the upper port of the hopper 305. Welding flux 307 is loaded in the hopper 305, and the welding flux 307 flows into the welding flux box 301 through the lower port of the hopper 305; The output end of the robotic arm 2 is fixedly connected to the welding flux box 301; A conductive nozzle mechanism 4 is arranged on the upper part of the welding box mechanism 3; A conveying mechanism 5 is arranged above the conductive nozzle mechanism 4.

[0032] Please refer to Figure 2 , Figure 3 , Figure 4 , Figure 5 , the positioning component includes a fixed seat 102 fixedly embedded in the bottom frame 101. The fixed seat 102 is U-shaped, and annular ring rails 103 are fixedly embedded at both ends of the fixed seat 102; Each ring rail 103 is movably installed with a ring frame component; The ring frame component includes an annular ring block 105. The ring block 105 is coaxial with the ring rail 103 and sleeved in the ring rail 103. A ring block 105 adapted to be inserted into the ring rail 103 is fixedly sleeved in the middle of the outer wall of the ring frame 104.

[0033] The lower side of the inner wall of the ring frame 104 is fixedly connected with a bottom wall 106, and one side of the inner wall of the ring frame 104 is fixedly connected with a side wall 107 perpendicular to the bottom wall 106. The side wall 107 and the bottom wall 106 are fixedly connected, and the ends of the bottom wall 106 and the side wall 107 both extend out of the ring frame 104; On the upper side of the inner wall of the ring frame 104, there is a clamping assembly opposite to the bottom wall 106. The clamping assembly includes an electric telescopic column 108 fixedly embedded in the ring frame 104. The output end of the electric telescopic column 108 is fixedly connected with a seat 109, and the lower side of the seat 109 is fixedly connected with a conveyor belt 110.

[0034] Please refer to Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13 , a door access control assembly is provided in the middle of the lower wall of the flux box 301; The door access control assembly includes a door panel groove 308, which is opened on the middle side of the bottom hole 303 and communicates with the bottom hole 303; Two door panels 309 are adaptively inserted in the door panel groove 308. The two door panels 309 are stacked, and through holes 310 are respectively penetrated through the middle of the surface of each door panel 309; One ends of the two door panels 309 facing away from each other are respectively fixedly connected with resilient plates 311. The ends of the resilient plates 311 away from the door panels 309 are bent and extend out of the lower wall of the flux box 301, and the ends of the resilient plates 311 are fixedly connected with counterweight bars 312; Initially, the two door panels 309 are misaligned to seal the bottom hole 303. When the lower wall of the welding box mechanism 3 contacts the cable tray, the counterweight bars 312 and the resilient plates 311 are pushed into the lower wall of the flux box 301, so that the two door panels 309 are facing each other, and the through holes 310 on them are facing each other, thus opening the bottom hole 303.

[0035] The nozzle mechanism 4 includes a nozzle 401 fixedly connected to the flux box 301. One end of the nozzle 401 corresponds to the top hole 302 and is fixedly connected with a guide ring 403, and the other end of the nozzle 401 is fixedly connected with a wire 402.

[0036] The conveying mechanism 5 includes a hollow conveying box 501. The middle of the upper wall of the conveying box 501 is penetrated with an inlet hole 502, and the middle of the lower wall of the conveying box 501 is penetrated with an outlet hole 503; The conveying box 501 is penetrated with a welding wire 504 through the inlet hole 502 and the outlet hole 503; The upper end of the guide ring 403 is fixedly connected to the conveying box 501 and communicates with the outlet hole 503. The welding wire 504 is inserted into the flux box 301 through the guide ring 403 and the nozzle 401. The welding wire 504 is adapted to the top hole 302 and the bottom hole 303, and the welding wire 504 is adapted to the through hole 310.

[0037] On one side inside the conveying box 501 and close to the outlet hole 503, a first driving wheel mechanism 6 is symmetrically arranged; Each first driving wheel mechanism 6 includes a fixing plate 601 fixedly connected to the conveying box 501. On one side of the fixing plate 601, a motor 602 is fixedly connected. The output end of the motor 602 is fixedly connected with a first pulley 603; The fixed end of the motor 602 is fixedly connected with a first shaft column 604. The first shaft column 604 is movably sleeved with a connecting arm 605 through a torsion spring. One end of the connecting arm 605 far from the first shaft column 604 is movably connected with a second shaft column 606 through a bearing. One end of the second shaft column 606 far from the connecting arm 605 is fixedly connected with a driving wheel 607 corresponding to the motor 602. A first friction strip 608 is fixedly connected to the outside of the driving wheel 607 at equal intervals and evenly. One end of the driving wheel 607 far from the second shaft column 606 is fixedly connected with a second pulley 609. The second pulley 609 and the first pulley 603 are jointly sleeved with a belt 610; The driving wheels 607 of the two first driving wheel mechanisms 6 are attached to the welding wire 504 from both sides.

[0038] On one side inside the conveying box 501 and close to the inlet hole 502, a second driving wheel mechanism 7 is symmetrically arranged; Each second driving wheel mechanism 7 includes an adjusting cylinder 701 fixedly connected to the conveying box 501. The output end of the adjusting cylinder 701 is fixedly connected with a U-shaped wheel seat 702. Through grooves 703 are respectively formed in the side wall surfaces of both sides of the wheel seat 702. A sensing component is arranged inside each through groove 703; The sensing component includes a strip column 704 vertically inserted into the through groove 703. Springs 705 are fixedly wound around both ends of the strip column 704 and are located inside the through groove 703; The wheel seat 702 is clamped with a wheel shaft 706 adapted to be inserted into the through groove 703. The middle part of the wheel shaft 706 is movably sleeved with a driven wheel 707 through a bearing. A second friction strip 708 is fixedly connected to the outside of the driven wheel 707 at equal intervals and evenly. The driven wheels 707 of the two second driving wheel mechanisms 7 are attached to the welding wire 504 from both sides; The strip column 704 penetrates through the wheel shaft 706, and the spring 705 abuts against the wheel shaft 706.

[0039] The working principle of the present invention is as follows: In the middle of the bottom wall of the flux box 301, an access control component is provided. When the bottom wall of the flux box 301 contacts the cable tray to be welded, the counterweight bar 312 and the resilient plate 311 are pushed inward into the bottom wall of the flux box 301 together. Through the pushing of the resilient plate 311, the two door panels 309 are pushed closer along the door panel slots 308, so that the through holes 310 opened on the surfaces of the two door panels 309 are aligned and communicate with the bottom holes 303 opened on the bottom wall of the flux box 301, enabling the flux 307 to flow through the bottom holes 303 and contact the cable tray. When the welding wire 504 melts and welds the cable tray, it is wrapped by the flux 307 to improve the welding safety.

[0040] When the robotic arm 2 drives the welding head assembly to move (away from the cable tray), by utilizing the gravity characteristic of the counterweight bar 312, without an additional power source, the counterweight bar 312 pulls the resilient plate 311 and then drives the door panel 309 to return to its position. The two door panels 309 are misaligned and together with the welding wire 504 passing through the through hole 310 seal the bottom hole 303, automatically triggering the reset action of the access control component. By synchronously pulling the two door panels 309 on both sides through the resilient plate 311, the bottom hole 303 opened on the bottom wall of the flux box 301 is completely closed, preventing the flux 307 from leaking during the movement of the welding head assembly from the source, avoiding polluting the working environment and wasting the flux 307, and saving costs.

[0041] The response driven by the gravity of the counterweight bar 312 is instantaneous and is coupled with the motion state of the robotic arm 2 in real time, forming a dynamic sealing effect of moving closure and positioning opening. The elastic deformation characteristic of the resilient plate 311 can buffer the inertial impact during the movement of the robotic arm 2, avoiding jamming or deformation of the door panel 309 caused by rigid connection. At the same time, it allows the two door panels 309 to move independently within a certain range, adapting to the attitude changes of the welding head assembly in complex trajectory movements, especially suitable for welding scenarios with multi-station switching or long-distance movement, ensuring the sealing reliability of the welding box mechanism 3 when the robotic arm 2 drives the welding head assembly to adjust the position state.

[0042] The second driving wheel mechanism 7 and the first driving wheel mechanism 6 are adopted at positions within the conveying box 501 and close to the inlet hole 502 and the outlet hole 503 respectively. The first driving wheel mechanism 6 is responsible for pushing the welding wire 504, passing the welding wire 504 through the flux box 301. The driving wheel 607 of the first driving wheel mechanism 6 clamps the welding wire 504 from both sides. The motor 602 is started to transmit power to the driving wheel 607 through the belt 610. The second driving wheel mechanism 7 monitors the conveying tension of the welding wire 504 in real time. First, the distance between the driven wheels 707 on both sides of the welding wire 504 is adjusted by the adjusting cylinder 701. During the process of conveying the welding wire 504, it floats along the sliding groove 703 through the driven wheels 707 and the wheel shaft 706. The tension generated by the movement of the welding wire 504 causes the driven wheels 707 to slide on the wheel seat 702. The displacement of the sliding of the driven wheels 707 is detected by the sensing component and recorded, and the adjusting cylinder 701 is dynamically adjusted in real time so that the distance between the two driven wheels 707 always remains within a suitable range; The driving wheel 607 of the first driving wheel mechanism 6 clamps the welding wire 504 from both sides, and the motor 602 and the belt 610 drive system provide stable pushing power for the welding wire 504, ensuring the stable long-distance conveying of the welding wire 504 from the conveying box 501 to the flux box 301 and then to the welding area. The first friction strips 608 are fixedly connected to the surface of the driving wheel 607 at equal intervals, increasing the contact area between the driving wheel 607 and the welding wire 504 and reducing the slipping rate of the welding wire 504. The second driving wheel mechanism 7 pre-adjusts the initial distance between the driven wheels 707 through the adjusting cylinder 701 to match welding wires 504 of different diameters; the elastic floating connection between the driven wheels 707 and the wheel seat 702 enables the driven wheels 707 to slide along the sliding groove 703 in real time with the change of tension, avoiding scratching or jamming of the welding wire 504 caused by rigid contact and improving the stability of the conveying of the welding wire 504.

[0043] The sensing component collects the sliding displacement of the driven wheels 707 in real time and linearly converts it into a real-time tension value. When the tension deviates from the set range, the control system automatically adjusts the air pressure of the adjusting cylinder 701 and dynamically corrects the distance between the two driven wheels 707. When the tension is too large, the thrust of the adjusting cylinder 701 is reduced, and the distance between the driven wheels 707 is enlarged to reduce the extrusion force; when the tension is too small, the air pressure of the adjusting cylinder 701 is increased, the distance between the driven wheels 707 is reduced, and the clamping force is increased, reducing the tension fluctuation, ensuring the wire feeding stability of the welding wire 504, and improving the dynamic tension adaptive adjustment ability of the conveying of the welding wire 504.

[0044] When the robotic arm 2 drives the welding head assembly to perform a large-angle flip, such as in the overhead welding posture or during high-speed movement, the driven wheels 707 can slide along the sliding groove 703, adapting to the path bending of the welding wire 504, compensating for the changes in inertial force and friction force through sliding, avoiding the wire feeding jamming problem in complex postures, improving the wire feeding stability, reducing the deviation of the weld formation, and improving the automatic welding quality.

[0045] By monitoring the tension of the welding wire 504 through the sensing component and limiting the conveying tension of the welding wire 504, a straightening force is formed when the first driving wheel mechanism 6 and the second driving wheel mechanism 7 convey the welding wire 504, a reverse bending moment is applied to the bent welding wire 504, and in cooperation with the first friction strip 608 on the surface of the driving wheel 607 and the second friction strip 708 on the surface of the driven wheel 707, the straightness of the welding wire 504 is improved, especially having a significant correction effect on the initial bending of the coiled welding wire 504.

[0046] The first driving wheel mechanism 6 and the second driving wheel mechanism 7 respectively form support fulcrums at the outlet hole 503 and the inlet hole 502 in the conveying box 501. In cooperation with the guiding ring 403 of the nozzle mechanism 4 between the conveying box 501 and the flux box 301, the coaxiality of the welding wire 504 is controlled within a certain range, ensuring that a uniform coating layer is formed when the welding wire 504 passes through the flux 307 at a uniform speed, avoiding the problem of the accumulation of the flux 307 caused by deflection, and improving the uniformity of the flux 307 coating the welding wire 504.

[0047] Aiming at the problem of the self-weight sag of the welding wire 504 during long-span conveying, the second driving wheel mechanism 7 automatically increases the supporting force through tension feedback, maintains the straightness of the welding wire 504, provides a basis for the arc stability during subsequent welding, and thus improves the arc welding quality.

[0048] Cable trays to be welded are respectively placed on the ring frame components on both sides of the retaining component. The cable trays are placed along the bottom attachment wall 106 and the side attachment wall 107 set by the ring frame components. The cable trays on both sides are opposite to each other at the middle position under the pressing of the clamping component and the pushing of the conveyor belt 110. Then, the welding head component is driven by the robotic arm 2 to push the cable trays from the outside, and the cable trays on both sides can be aligned and fitted with each other through the cooperation with the side attachment wall 107, improving the accuracy of butt joint before welding.

[0049] The flux 307 in the flux box 301 can be poured onto the surface of the cable tray along the bottom hole 303 opened on the bottom wall of the flux box 301 under the action of gravity. Therefore, when the flux 307 needs to cover the surface of the weld seam, the ring frame component can be driven to flip along the bottom hole 303, thus avoiding the inversion of the flux box 301. If the required welding precision is not high, the flux box 301 can also be flipped by flipping the robotic arm 2, so as to directly weld the weld seam on the lower wall of the cable tray, adapting to the welding precision to adjust the welding method and improving the use flexibility.

[0050] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An automatic welding system for a large-span cable tray, comprising a frame mechanism (1), the frame mechanism (1) includes a bottom frame (101), a positioning component for docking the cable tray is arranged on the bottom frame (101), and a welding component corresponding to the positioning component is arranged on the bottom frame (101); It is characterized in that: The welding component includes a robotic arm (2) fixedly connected to the bottom frame (101) and a welding head component; The welding head component includes a welding box mechanism (3), the welding box mechanism (3) includes a hollow welding flux box (301), a top hole (302) is penetrated and opened in the middle of the upper wall of the welding flux box (301), and a bottom hole (303) corresponding to the top hole (302) is penetrated and opened in the middle of the lower wall of the welding flux box (301); One end of the upper wall of the welding flux box (301) is fixedly communicated with a connecting pipe (304), a funnel-shaped hopper (305) is fixedly inserted at the end of the connecting pipe (304), the lower port of the hopper (305) is inserted into the welding flux box (301), a hopper cover (306) is fixedly clamped at the upper port of the hopper (305), and welding flux (307) is loaded in the hopper (305); The output end of the robotic arm (2) is fixedly connected to the welding flux box (301); A conductive nozzle mechanism (4) is arranged above the welding box mechanism (3); A conveying mechanism (5) is arranged above the conductive nozzle mechanism (4).

2. The automatic welding system for a long-span cable tray according to claim 1, characterized in that: The positioning component includes a fixed seat (102) fixedly embedded in the bottom frame (101), the fixed seat (102) is U-shaped, and annular ring rails (103) are fixedly embedded at both ends of the fixed seat (102); Each of the ring rails (103) is movably installed with a ring frame component; The ring frame component includes an annular ring block (105), the ring block (105) is coaxial with the ring rail (103) and sleeved in the ring rail (103), and a ring block (105) adapted to be inserted into the ring rail (103) is fixedly sleeved in the middle of the outer wall of the ring of the ring frame (104).

3. The automatic welding system for a large-span cable tray according to claim 2, characterized in that: A bottom attaching wall (106) is fixedly connected to the lower side of the inner wall of the ring of the ring frame (104), a side attaching wall (107) perpendicular to the bottom attaching wall (106) is fixedly connected to one side of the inner wall of the ring of the ring frame (104), the side attaching wall (107) and the bottom attaching wall (106) are fixedly connected, and the ends of the bottom attaching wall (106) and the side attaching wall (107) both extend out of the ring frame (104); A clamping component is arranged on the upper side of the inner wall of the ring of the ring frame (104) opposite to the bottom attaching wall (106), the clamping component includes an electric telescopic column (108) fixedly embedded in the ring frame (104), the output end of the electric telescopic column (108) is fixedly connected to a seat (109), and a conveyor belt (110) is fixedly connected to the lower side of the seat (109).

4. The automatic welding system for a large-span cable tray according to claim 1, wherein: A door control component is arranged in the middle of the lower wall of the welding flux box (301); The door control component includes a door plate groove (308), the door plate groove (308) is opened at the middle side of the bottom hole (303) and communicated with the bottom hole (303); Two door panels (309) are adaptively inserted into the door panel groove (308), and the two door panels (309) are stacked. A through hole (310) is formed through the middle of the surface of each door panel (309); One end of each of the two door panels (309) facing away from each other is fixedly connected with a resilient plate (311). The end of the resilient plate (311) away from the door panel (309) is bent and extends out of the lower wall of the flux box (301). The end of the resilient plate (311) is fixedly connected with a counterweight strip (312).

5. The automatic welding system for a long-span cable tray according to claim 4, characterized in that: The nozzle mechanism (4) includes a nozzle (401) fixedly connected to the flux box (301). One end of the nozzle (401) corresponds to the top hole (302) and is fixedly connected with a guide ring (403). The other end of the nozzle (401) is fixedly connected with a wire (402).

6. The automatic welding system for a large-span cable tray according to claim 5, characterized in that: The conveying mechanism (5) includes a hollow conveying box (501). A through hole (502) is formed through the middle of the upper wall of the conveying box (501), and a through hole (503) is formed through the middle of the lower wall of the conveying box (501); A welding wire (504) is inserted through the conveying box (501) through the inlet hole (502) and the outlet hole (503); The upper end of the guide ring (403) is fixedly connected to the conveying box (501) and communicates with the outlet hole (503). The welding wire (504) is inserted into the flux box (301) through the guide ring (403) and the nozzle (401). The welding wire (504) is adapted to the top hole (302) and the bottom hole (303), and the welding wire (504) is adapted to the through hole (310).

7. The automatic welding system for a large-span cable tray according to claim 6, characterized in that: On one side of the inside of the conveying box (501) and close to the outlet hole (503), a first driving wheel mechanism (6) is symmetrically arranged; Each first driving wheel mechanism (6) includes a fixed plate (601) fixedly connected to the conveying box (501). A motor (602) is fixedly connected to one side of the fixed plate (601). The output end of the motor (602) is fixedly connected with a first pulley (603); The fixed end of the motor (602) is fixedly connected with a first shaft column (604). The first shaft column (604) is movably sleeved with a connecting arm (605) through a torsion spring. One end of the connecting arm (605) away from the first shaft column (604) is movably connected with a second shaft column (606) through a bearing. One end of the second shaft column (606) away from the connecting arm (605) is fixedly connected with a driving wheel (607) corresponding to the motor (602). A first friction strip (608) is fixedly connected to the outside of the driving wheel (607) at equal intervals and evenly. One end of the driving wheel (607) away from the second shaft column (606) is fixedly connected with a second pulley (609). The second pulley (609) and the first pulley (603) are jointly sleeved with a belt (610); The driving wheels (607) of the two first driving wheel mechanisms (6) are attached to the welding wire (504) from both sides.

8. The automatic welding system for a long-span cable tray according to claim 7, wherein: On one side of the inside of the conveying box (501) and close to the inlet hole (502), a second driving wheel mechanism (7) is symmetrically arranged; Each of the second driving wheel mechanisms (7) includes an adjusting cylinder (701) fixedly connected to the conveying box (501). The output end of the adjusting cylinder (701) is fixedly connected to a U-shaped wheel seat (702). Through grooves (703) are respectively formed in the two side wall surfaces of the wheel seat (702), and a sensing component is arranged inside each through groove (703). The sensing component includes a strip column (704) vertically inserted into the through groove (703). Springs (705) are fixedly wound around both ends of the strip column (704) and are located inside the through groove (703). The wheel seat (702) is clamped with a wheel shaft (706) adapted to be inserted into the through groove (703). A driven wheel (707) is movably sleeved on the middle part of the wheel shaft (706) through a bearing. Second friction strips (708) are fixedly connected to the outside of the driven wheel (707) at equal intervals and evenly. The driven wheels (707) of the two second driving wheel mechanisms (7) are attached to the welding wire (504) from both sides. The strip column (704) penetrates through the wheel shaft (706), and the spring (705) is attached to the wheel shaft (706).

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