Robot electrode holder electrode cap centering detection device

Abstract

The invention discloses a centering detection device for an electrode cap of a robot electrode holder, and aims to solve the problems that in the prior art, manual measurement is low in efficiency and affects the production schedule, and a three-coordinate measuring instrument is low in measurement efficiency and difficult to measure on a production line. Measurement is started through self-triggering of the centering detection device, and automatic line edge measurement is achieved in cooperation with movement track setting of the robot electrode holder. The centering detection device comprises a laser measurement box which comprises a plurality of laser displacement sensors and is used for measuring the displacement of an upper electrode cap and a lower electrode cap and sending measured values to a data acquisition and calculation control unit; the data acquisition and calculation control unit is used for receiving a measurement value of the laser measurement box, performing A / D conversion, calculating a measurement result and sending data to the data recording and displaying system; and the data recording and displaying system is used for displaying and storing the measurement result and giving an alarm according to a preset standard or requirement. Therefore, the defects of a traditional measurement mode are overcome, and the measurement efficiency and precision are effectively improved.

Description

Technical Field

[0001] The present application relates to the field of welding technology, and in particular to a robot welding clamp detection device. Background Art

[0002] With the booming automotive manufacturing industry, controlling the welding quality of the body welding production line is crucial. Robotic welding tongs are the core equipment for improving welding efficiency and quality. The centering accuracy of their electrode caps directly affects the welding results. Traditional measurement methods have many drawbacks:

[0003] First, manual measurement using a ruler and a plug gauge is cumbersome and inefficient. Moreover, since the measurement process requires the line to be stopped, it greatly affects the production progress and makes it difficult to meet the requirements of modern production lines for efficient and continuous production.

[0004] Secondly, although the three-dimensional coordinate measuring machine has high measurement accuracy, its measurement efficiency is low, and the equipment is complex and expensive. It is difficult to perform real-time and convenient measurements on the production line, and it is impossible to promptly detect and deal with electrode cap alignment problems that may occur during the welding process. Summary of the Invention

[0005] The present application provides a robot welding clamp electrode cap alignment detection device, which aims to solve the problems in the prior art of low manual measurement efficiency, affecting production progress, and low measurement efficiency of three-coordinate measuring instruments, which are difficult to measure on the production line.

[0006] In the first aspect, a centering detection device for the electrode cap of a robot welding clamp is provided. The centering detection device self-triggers and starts measurement, and cooperates with the motion trajectory setting of the robot welding clamp to realize automatic line edge measurement. The centering detection device includes: a laser measurement box, a data acquisition and calculation control unit, and a data recording and display system.

[0007] A laser measurement box, whose data output end is electrically connected to the input end of the data acquisition and calculation control unit, the laser measurement box includes a first laser displacement sensor t1, a second laser displacement sensor t2, a third laser displacement sensor t3 and a fourth laser displacement sensor t4; it is used to measure the displacement of the upper and lower electrode caps and send the measured values to the data acquisition and calculation control unit, wherein the first laser displacement sensor t1 and the second laser displacement sensor t2 form a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 form another group; each group of laser displacement sensors is arranged along the axis direction of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper electrode cap and the lower electrode cap, and the measurement direction of each group of laser displacement sensors is parallel to and aligned with the measurement direction of the other group of laser displacement sensors The measuring directions of the sensors are exactly orthogonal. Four laser displacement sensors are arranged on the periphery of the upper and lower electrode caps of the robot welding clamp, and a non-contact measurement method is adopted. The first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in a first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in a second direction, and the second direction is orthogonal to the first direction; the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction; the upper and lower electrode caps are always located within the measurement range of the corresponding laser displacement sensor, and the first laser displacement sensor t1 is always in a measuring state, and automatically judges and starts the measurement process according to the movement trajectory of the robot.

[0008] The data acquisition and calculation control unit has an input end electrically connected to the data output end of the laser measurement box, and an output end electrically connected to the input end of the data recording and display system, and is used to receive the measurement value of the laser measurement box and perform A / D conversion, calculate the measurement result, and send the data to the data recording and display system.

[0009] The data recording and display system has an input terminal electrically connected to the output terminal of the data acquisition and calculation control unit, and is used to display and store measurement results and issue an alarm according to preset standards or requirements.

[0010] In the above solution, optionally, the formula for measuring the actual displacement of the upper and lower electrode caps is as follows.

[0011]

[0012] in, Indicates the relative offset of the upper and lower electrode caps between the current moment and the previous moment, that is, the actual displacement of the upper and lower electrode caps between the current moment and the previous moment; Indicates the displacement change of the first laser displacement sensor t1 between the current moment and the previous moment; Indicates the displacement change of the second laser displacement sensor t2 between the current moment and the previous moment; Indicates the displacement change of the third laser displacement sensor t3 between the current moment and the previous moment; Indicates the displacement change of the fourth laser displacement sensor t4 between the current moment and the previous moment.

[0013] In the above scheme, optionally, the geometric center of the upper electrode cap is used as the coordinate origin, the measuring direction of the first laser displacement sensor t1 is used as the x-axis, and the measuring direction of the third laser displacement sensor t3 is used as the y-axis; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the y-axis direction.

[0014] In the above scheme, further optionally, the first laser displacement sensor t1 is used to measure the distance between its laser emitting end and the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the distance between its laser emitting end and the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the distance between its laser emitting end and the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the distance between its laser emitting end and the lower electrode cap in the y-axis direction.

[0015] In the above solution, optionally, the distances between the first laser displacement sensor t1 , the second laser displacement sensor t2 , the third laser displacement sensor t3 and the fourth laser displacement sensor t4 and the welding clamp body are fixed.

[0016] In the above solution, optionally, the device needs to be manually inspected and aligned with the positions of the upper and lower electrode caps before first use, that is, initial calibration or zero point calibration.

[0017] In the above solution, optionally, the device calculates the actual displacement of the upper and lower electrode caps in real time when in use. , until the actual displacement Less than the preset value.

[0018] In the above scheme, optionally, the first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3 and the fourth laser displacement sensor t4 use infrared laser sensors, and when the four laser displacement sensors are in working state, the upper and lower electrode caps are always located within the measurement range of the corresponding laser displacement sensors.

[0019] In the above solution, optionally, the data acquisition and calculation control unit includes an acquisition card, a calculation control unit and a power supply module.

[0020] The input end of the acquisition card is electrically connected to the data output end of the laser measurement box, the output end is electrically connected to the input end of the calculation control unit, and the power end is connected to the power module; the data acquisition card performs A / D conversion on the measurement value received from the laser measurement box and sends it to the calculation control unit.

[0021] The input end of the calculation control unit is electrically connected to the output end of the data acquisition card, the output end is electrically connected to the data recording and display system, and the power supply end is connected to the power supply module; the calculation control unit is used to process and calculate the digital signal transmitted by the acquisition card, obtain the offset of the electrode cap, and send the result to the data recording and display system.

[0022] The power supply module is connected to the acquisition card and the calculation control unit and supplies power to them.

[0023] In a second aspect, a method for detecting the centering of an electrode cap of a robot welding clamp is provided. The method uses the above-mentioned device for detecting the centering of an electrode cap of a robot welding clamp to perform detection, and the method includes the following contents.

[0024] After the initial calibration is completed and the centering detection device is powered on, the first laser displacement sensor t1 automatically determines and starts the measurement process based on the movement trajectory of the robot.

[0025] After the first laser displacement sensor t1 starts the measurement process, the laser measurement box inputs the displacement measurement values of the upper and lower electrode caps collected in real time into the data acquisition and calculation control unit. Specifically, the laser measurement box includes: the first laser displacement sensor t1 and the second laser displacement sensor t2 form a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 form another group; each group of laser displacement sensors is arranged along the axis of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper and lower electrode caps. The measurement direction of each group of laser displacement sensors is parallel and exactly orthogonal to the measurement direction of the other group of laser displacement sensors. The four laser displacement sensors are arranged on the periphery of the upper and lower electrode caps of the robot welding clamp and adopt a non-contact measurement method; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in a first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in a second direction, the second direction being orthogonal to the first direction; and the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction.

[0026] The data acquisition and calculation control unit receives the displacement data of the upper and lower electrode caps measured by the laser measurement box in real time and performs A / D conversion. Based on the data measured by the first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3 and the fourth laser displacement sensor t4, the relative offset of the upper and lower electrode caps at the current moment and the previous moment, that is, the actual displacement of the upper and lower electrode caps, is calculated and sent to the data recording and display system in real time.

[0027] The data recording and display system displays and stores the actual displacement data of the upper and lower electrode caps sent by the data acquisition and calculation control unit in real time, and issues an alarm according to preset standards or requirements.

[0028] Compared with the prior art, this application has at least the following beneficial effects.

[0029] This application is based on further analysis and research on the problems of the existing technology, and recognizes that the existing technology has the problems of low efficiency of manual measurement, which affects the production progress, and low efficiency of three-dimensional coordinate measuring instruments, which are difficult to measure on the production line. By adopting a laser measuring box, multiple laser displacement sensors are arranged in a four-point orthogonal non-contact manner on the periphery of the electrode cap of the robot welding clamp, which can quickly and accurately measure the actual displacement of the electrode cap; cooperate with the data acquisition and calculation control unit to perform A / D conversion and measurement result calculation, and the data recording and display system to display, store and alarm data, thereby realizing efficient and automated measurement of the centering condition of the electrode cap of the robot welding clamp, effectively improving the measurement efficiency and accuracy, and not affecting the normal operation of the production line, thereby overcoming the shortcomings of traditional measurement methods and meeting the urgent needs of the automobile manufacturing industry for welding quality control.

[0030] This application also utilizes a four-point orthogonal non-contact setup: four laser displacement sensors (T1, T2, T3, and T4) are installed orthogonally, two at a time. This layout ensures accurate monitoring of electrode cap position changes, even in complex working environments, thereby improving welding quality and production efficiency. Furthermore, the use of non-contact measurement helps reduce mechanical wear and extend the life of the measurement system. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A schematic diagram of the application environment of a robot welding clamp electrode cap alignment detection device provided in one embodiment of the present application.

[0032] Figure 2 A schematic diagram of the position layout of laser displacement sensors provided in one embodiment of the present application.

[0033] Figure 3A schematic diagram of the connection relationship of a robot welding clamp electrode cap alignment detection device provided in one embodiment of the present application.

[0034] Figure 4 A schematic flow chart of a method for detecting the centering of an electrode cap of a robot welding clamp provided in one embodiment of the present application. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of this application more clear, the following further describes this application in detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0036] In the description of this application: unless otherwise specified, "plurality" means two or more. The terms "first," "second," "third," etc. in this application are intended to distinguish the objects referred to and do not have any special technical connotations (for example, they should not be understood as emphasizing importance or order). Expressions such as "including," "comprising," and "having" also mean "not limited to" (certain units, components, materials, steps, etc.).

[0037] Robot welding tongs are widely used in the body welding production lines of the automobile manufacturing industry. The centering accuracy of the upper and lower electrode caps of the movable and static arms of the robot welding tongs has a direct impact on the welding quality. The centering error is generally required to be Not more than 0.5mm, such as Figure 1 shown.

[0038] There are currently two methods for measuring the centering of electrodes in robotic welding tongs: (1) Manual measurement using a ruler and a feeler gauge is inefficient and requires the production line to be stopped for inspection. (2) Measurement using a three-dimensional coordinate measuring machine has high measurement accuracy, but is inefficient and difficult to perform on the production line.

[0039] Therefore, developing a centering detection device that can self-trigger measurement and automatically measure the edge of the weld in conjunction with the motion trajectory of a robotic welding clamp has become a key requirement for improving welding quality and production efficiency in the automotive manufacturing industry. This device must be efficient, accurate, and highly automated to overcome the limitations of traditional measurement methods and meet the fast-paced production demands of modern automotive production lines.

[0040] Therefore, in one embodiment, reference Figure 2 and Figure 3 , provides a robot welding clamp electrode cap centering detection device, the centering detection device self-triggering to start measurement, combined with the robot welding clamp motion trajectory setting to achieve automatic line edge measurement; the centering detection device includes: a laser measuring box, a data acquisition and calculation control unit and a data recording and display system.

[0041] The laser measurement box has a data output terminal electrically connected to the input terminal of the data acquisition and calculation control unit. The laser measurement box includes a first laser displacement sensor t1, a second laser displacement sensor t2, a third laser displacement sensor t3 and a fourth laser displacement sensor t4; it is used to measure the displacement of the upper and lower electrode caps and send the measured values to the data acquisition and calculation control unit, wherein the first laser displacement sensor t1 and the second laser displacement sensor t2 form a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 form another group; each group of laser displacement sensors is arranged along the axis direction of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper electrode cap and the lower electrode cap, and the measurement value of each group of laser displacement sensors is 0.01. The measurement direction is parallel and exactly orthogonal to the measurement direction of another group of laser displacement sensors. The four laser displacement sensors are arranged on the periphery of the upper and lower electrode caps of the robot welding clamp and adopt a non-contact measurement method; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in the first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in the second direction, and the second direction is orthogonal to the first direction; the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction; the first laser displacement sensor t1 is always in the measurement state, and automatically determines and starts the measurement process according to the movement trajectory of the robot.

[0042] The data acquisition and calculation control unit has an input end electrically connected to the data output end of the laser measurement box, and an output end electrically connected to the input end of the data recording and display system. It is used to receive the measurement value of the laser measurement box and perform A / D conversion, calculate the measurement result, and send the data to the data recording and display system.

[0043] The data recording and display system has an input terminal electrically connected to the output terminal of the data acquisition and calculation control unit, and is used to display and store measurement results and issue an alarm according to preset standards or requirements.

[0044] This application consists of a laser measurement box, a data acquisition and calculation controller, and a data recording and display system.

[0045] The laser measurement box consists of four laser displacement sensors: T1, T2, T3, and T4. They measure the actual displacement of the upper and lower electrode caps. Sensor T1 is always in the measurement state, automatically determining and initiating the measurement process based on the robot's motion trajectory. Sensors T2, T3, and T4 can also be in the measurement state. The designation of the first, second, third, and fourth laser displacement sensors in this application is not intended to limit their order, but rather to facilitate distinguishing and describing the positions of the different sensors.

[0046] The measurement acquisition and control unit consists of an acquisition card, a calculation control unit, and a power supply module.

[0047] Start the measurement process, perform A / D conversion on the measurement values of the four laser position sensors, calculate the measurement results, and send the data to the display system.

[0048] The data recording and display system consists of a computer and corresponding software. It is used to display and store measurement results and issue alarms according to set standards or customer requirements.

[0049] This application uses a 4-point orthogonal non-contact laser displacement sensor to measure the actual displacement of the upper and lower electrode caps and calculate the relative offset of the upper and lower electrode caps. The measurement system automatically triggers the measurement and cooperates with the robot motion trajectory setting to achieve automatic line-edge measurement.

[0050] In this embodiment, the laser displacement sensors are arranged in groups of two along the axis of the electrode cap, and each group of laser displacement sensors is respectively aligned with the center of the upper electrode cap and the lower electrode cap. The measurement directions of each group of laser displacement sensors are orthogonal to each other and are used to measure the displacement of the upper and lower electrode caps in two mutually perpendicular directions. The laser displacement sensors are arranged on the periphery of the electrode cap of the robot welding clamp and adopt non-contact measurement.

[0051] In this embodiment, four laser displacement sensors are arranged around the periphery of the electrode cap of the robot welding tongs. These sensors are grouped in pairs, aligned with the center of the upper and lower electrode caps, respectively. Two sensor groups, each with two sensors, monitor the upper and lower electrode caps, respectively. The two sensors in each sensor group are arranged one above the other along the axis of the electrode cap, ensuring that axial displacement of the electrode cap can be captured.

[0052] The two laser displacement sensors in each group measure in perpendicular directions (i.e., orthogonal to each other), allowing the displacement of the electrode cap to be measured in two mutually perpendicular directions. This allows for more comprehensive spatial position information of the electrode cap to be obtained.

[0053] All laser displacement sensors use a non-contact measurement method, which helps reduce mechanical wear and allows high-precision measurements without disturbing the target object (electrode cap).

[0054] This layout design enables the system to accurately monitor the position changes of the electrode cap during operation, which is crucial for improving welding quality and efficiency. Thanks to its use of non-contact laser measurement technology, the system also provides reliable measurement results in high-temperature or inaccessible working environments. Furthermore, by aligning the sensor measurement directions orthogonally, the displacement of the electrode cap in multiple dimensions can be effectively captured, providing accurate data support for subsequent control and adjustment.

[0055] In one embodiment, the formula for measuring the actual displacement of the upper and lower electrode caps is as follows.

[0056] .

[0057] in, Indicates the relative offset of the upper and lower electrode caps between the current moment and the previous moment, that is, the actual displacement of the upper and lower electrode caps between the current moment and the previous moment; Indicates the displacement change of the first laser displacement sensor t1 between the current moment and the previous moment; Indicates the displacement change of the second laser displacement sensor t2 between the current moment and the previous moment; Indicates the displacement change of the third laser displacement sensor t3 between the current moment and the previous moment; Indicates the displacement change of the fourth laser displacement sensor t4 between the current moment and the previous moment.

[0058] Laser displacement sensors t1 and t2 are at 90 degrees to t3 and t4. The positions of the upper and lower electrode caps are measured from t1 to t4, with offset values of Δt1 to Δt4. The formula for calculating the relative offset of the upper and lower electrode caps is as follows.

[0059] .

[0060] The four laser displacement sensors are t1, t2, t3, and t4. Each sensor set (t1 and t2, and t3 and t4) is aligned with the center of the upper and lower electrode caps, respectively, to perform non-contact displacement measurement. Because the two sensor sets are arranged at a 90-degree angle, this setup allows the system to independently measure the displacement of the electrode caps in two mutually perpendicular directions, providing more precise position information.

[0061] This method effectively monitors the position changes of the electrode cap, ensuring highly accurate measurement results even in complex operating environments. This design not only improves welding quality but also enhances the efficiency of automated production. Furthermore, the use of a non-contact laser displacement sensor reduces wear between mechanical components, extending equipment life and reducing maintenance costs.

[0062] In one embodiment, the structure of the four laser displacement sensors is arranged as follows: the geometric center of the upper electrode cap is used as the coordinate origin, the measuring direction of the first laser displacement sensor t1 is used as the x-axis, and the measuring direction of the third laser displacement sensor t3 is used as the y-axis; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the y-axis direction.

[0063] In one embodiment, the first laser displacement sensor t1 is used to measure the distance between its laser emitting end and the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the distance between its laser emitting end and the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the distance between its laser emitting end and the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the distance between its laser emitting end and the lower electrode cap in the y-axis direction.

[0064] In this embodiment, the first direction is the x-axis direction, and the second direction is the y-axis direction.

[0065] In this embodiment, the user only needs to use the simplest infrared laser displacement sensor. The displacement value of the electrode cap can be obtained by subtracting the measured value at this moment from the distance between the laser emitting end and the upper / lower electrode cap in their respective directions of different laser displacement sensors: for example, the measurement value of the first laser displacement sensor t1 at the current moment and the previous moment is recorded and subtracted to obtain the displacement value of the upper electrode cap in the x-axis direction at the current moment and the previous moment. Similarly, the displacement value of the upper electrode cap in the y-axis direction at the current moment and the previous moment, the displacement value of the lower electrode cap in the x-axis direction at the current moment and the previous moment, and the displacement value of the lower electrode cap in the y-axis direction at the current moment and the previous moment can be obtained. Substituting each displacement value into the formula of the relative offset of the upper and lower electrode caps can obtain the actual displacement of the upper and lower electrode caps.

[0066] In one embodiment, the first laser displacement sensor t1 , the second laser displacement sensor t2 , the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are located at a fixed distance from the welding clamp body.

[0067] In this application, the centering detection device is mounted on the fixed portion of the robot's welding tongs, so it moves with the overall movement of the tongs. This ensures that the sensor is aligned with the electrode cap for measurement at various welding positions. Although the centering detection device moves with the tongs, it must be able to accurately measure minute displacements of the electrode cap relative to the sensor. This is because the electrode cap may deviate slightly during welding due to factors such as wear and arc force, and these deviations need to be detected promptly to ensure weld quality.

[0068] In one embodiment, as an illustrative example, the welding clamp body is selected as the installation reference for the centering detection device. Because the electrode caps of the robotic welding clamp need to be detected for alignment, this application utilizes the aforementioned arrangement method to place four laser displacement sensors (the core of the centering detection device) around the upper and lower electrode caps to detect offset. Furthermore, the centering detection device simultaneously coordinates with the motion trajectory of the robotic welding clamp to achieve automatic line-edge measurement. In other words, the centering detection system monitors the offset of the upper and lower electrode caps of the welding clamp based on four laser displacement sensors. However, the robotic welding clamp itself is in motion, so a clear installation reference for the sensors is required to achieve the present application's goal of detecting offset of the electrode caps.

[0069] In some embodiments, the wire-side bracket (if any) can also be selected as the installation reference for the centering detection device. Alternatively, in other embodiments, the geometric center of the upper electrode cap or the lower electrode cap is used as the installation reference for the centering detection device. In actual use, as long as the centering detection device 1) can move with the motion trajectory of the welding clamp and 2) can detect the relative displacement of the electrode cap, the user can install the centering detection device in any installation method at any position on the welding clamp. In other words, as long as the above two points are met, the centering detection device can select any installation reference, and this application does not impose specific restrictions.

[0070] In one embodiment, the first laser displacement sensor t1 and the second laser displacement sensor t2 are at the same distance from the welding clamp body, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are at the same distance from the welding clamp body.

[0071] In this embodiment, the first laser displacement sensor t1 and the second laser displacement sensor t2 are initially positioned at the same distance from the upper electrode cap, while the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are initially positioned at the same distance from the lower electrode cap. This means that initially, the positions of t1 and t2 relative to the upper electrode cap are identical, and the positions of t3 and t4 relative to the lower electrode cap are also identical. However, as the welding process progresses, the electrode cap may shift, causing the distance between the sensor and the electrode cap to change. By measuring these changes, the displacement of the electrode cap can be calculated.

[0072] In another embodiment, the first laser displacement sensor t1 , the second laser displacement sensor t2 , the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are all at the same distance from the welding clamp body.

[0073] In this embodiment, the first and second laser displacement sensors t1 and t2 are initially located at a first distance from the upper electrode cap, while the third and fourth laser displacement sensors t3 and t4 are initially located at a second distance from the lower electrode cap. In this embodiment, the first distance equals the second distance. This means that, initially, all sensors are located at the same distance relative to their corresponding electrode caps. Similarly, as the welding process progresses, the displacement of the electrode caps causes changes in the distances between the corresponding sensors and the electrode caps. These changes can be used to calculate the displacement of the electrode caps.

[0074] In actual applications, users can determine the distance between the four laser sensors and the welding clamp body according to the specific situation. Due to different factory environments and structural differences in welding equipment, the space left for the laser sensors may not be a standard square or circle, but various irregular shapes. Therefore, the installation position of the sensor may be subject to certain restrictions. However, the core of this application is to measure the relative offset between the upper and lower electrode caps, rather than the absolute position. This means that as long as the relative position between the sensor and the welding clamp body or the mounting reference remains fixed during the measurement process, the relative displacement of the electrode caps can be accurately measured. Therefore, users can flexibly choose the installation position of the sensor according to the actual spatial conditions, as long as these positions are ensured to remain unchanged during the measurement process.

[0075] In one embodiment, before the device is used for the first time, manual detection and alignment of the positions of the upper and lower electrode caps are required, namely, initial calibration or zero point calibration.

[0076] In this embodiment, upon initial use, the upper and lower electrode caps must be aligned to the desired design centering, and the device's measurement reference must be set to zero using a calibration tool. After this initial calibration, the device uses a laser displacement sensor to measure the actual displacement of the electrode caps and determines their alignment based on a pre-set algorithm. If deviation is detected, the device automatically issues an alarm or makes adjustments.

[0077] Calibration ensures that a device can accurately measure or operate in its initial state. A calibrated device is more reliable during use and provides more stable results.

[0078] In one embodiment, the device calculates the actual displacement of the upper and lower electrode caps in real time during use. , until the actual displacement Less than the preset value.

[0079] The device can calculate the actual displacement of the upper and lower electrode caps in real time during use , and stops calculating when the displacement is less than the preset value. This function ensures that the electrode cap always remains in the centered state, improving welding quality and production efficiency, while reducing manual intervention and increasing the degree of automation.

[0080] In one embodiment, the first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3 and the fourth laser displacement sensor t4 use infrared laser sensors, and when the four laser displacement sensors are in working state, the upper and lower electrode caps are always located within the measurement range of the corresponding laser displacement sensors.

[0081] Although ideally, an infrared laser sensor emits a single laser line, in practice, it emits a laser beam with a specific width and range. In actual production environments, the position of the upper and lower electrode caps must be manually inspected and aligned before the device is used for the first time. Due to this initial alignment, the upper and lower electrode caps are already within the laser sensor's measurement range, ensuring that the laser sensor cannot detect them. Furthermore, any subsequent displacements are minute, and because the laser beam itself has a specific width and range, even if the upper and lower electrode caps undergo slight displacements, they remain within the infrared laser sensor's measurement range. The sensor can continuously and accurately monitor changes in the electrode caps' positions, ensuring measurement stability and reliability.

[0082] In one embodiment, the data acquisition and calculation control unit includes an acquisition card, a calculation control unit, and a power supply module.

[0083] The input end of the acquisition card is electrically connected to the data output end of the laser measurement box, the output end is electrically connected to the input end of the calculation control unit, and the power end is connected to the power module; the data acquisition card performs A / D conversion on the measurement value received from the laser measurement box and sends it to the calculation control unit.

[0084] The input end of the calculation control unit is electrically connected to the output end of the data acquisition card, the output end is electrically connected to the data recording and display system, and the power supply end is connected to the power supply module; the calculation control unit is used to process and calculate the digital signal transmitted by the acquisition card, obtain the offset of the electrode cap, and send the result to the data recording and display system.

[0085] The power module connects the acquisition card and the computing control unit and provides power to them.

[0086] In this embodiment, the data acquisition and calculation control unit includes a data acquisition card, a calculation control unit and a power supply module, which are used to process the data obtained from the laser measurement box and ultimately calculate the offset of the electrode cap.

[0087] The data acquisition card receives the data output from the laser measurement box. This process converts the analog signal (the laser measurement box's measurement value) into a digital signal via an A / D converter. The data acquisition card's input is electrically connected to the laser measurement box's data output, while its output is connected to the input of the computational control unit. Furthermore, the data acquisition card's power supply is connected to the power module for necessary electrical support.

[0088] The calculation control unit receives the digitized measurements transmitted by the data acquisition card. Its primary task is to process this data and perform the necessary calculations to determine the electrode cap deflection. Once the calculations are complete, the results are sent to the data recording and display system for easy viewing and recording. The calculation control unit's input is connected to the output of the data acquisition card, which in turn is connected to the data recording and display system. The calculation control unit also requires power from a power supply module via its power supply terminal.

[0089] The power supply module ensures the normal operation of the data acquisition card and the calculation control unit. It is connected to the data acquisition card and the calculation control unit respectively.

[0090] Data acquisition and calculation control unit help improve welding accuracy and efficiency, while also enhancing the level of automation.

[0091] In one embodiment, reference Figure 4 A method for detecting the centering of the electrode cap of a robot welding clamp is provided. The method uses the device for detecting the centering of the electrode cap of a robot welding clamp provided in the above embodiment to perform detection. The method comprises:

[0092] After the initial calibration is completed and the centering detection device is powered on, the first laser displacement sensor t1 automatically determines and starts the measurement process based on the movement trajectory of the robot.

[0093] After the first laser displacement sensor t1 starts the measurement process, the laser measurement box inputs the displacement measurement values of the upper and lower electrode caps collected in real time into the data acquisition and calculation control unit. Specifically, the laser measurement box includes: the first laser displacement sensor t1 and the second laser displacement sensor t2 form a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 form another group; each group of laser displacement sensors is arranged along the axis of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper and lower electrode caps. The measurement direction of each group of laser displacement sensors is parallel and exactly orthogonal to the measurement direction of the other group of laser displacement sensors. The four laser displacement sensors are arranged on the periphery of the upper and lower electrode caps of the robot welding clamp and adopt a non-contact measurement method; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in a first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in a second direction, the second direction being orthogonal to the first direction; and the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction.

[0094] The data acquisition and calculation control unit receives the displacement measurement values of the upper and lower electrode caps measured by the laser measurement box in real time, and performs A / D conversion. Based on the data measured by the first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3 and the fourth laser displacement sensor t4, it calculates the relative offset of the upper and lower electrode caps at the current moment and the previous moment, that is, the actual displacement of the upper and lower electrode caps, and sends the actual displacement to the data recording and display system in real time.

[0095] The data recording and display system displays and stores the actual displacement data of the upper and lower electrode caps sent by the data acquisition and calculation control unit in real time, and issues an alarm according to preset standards or requirements.

[0096] In this embodiment, the data acquisition and calculation control unit specifically includes the following contents.

[0097] The data acquisition card is responsible for receiving the displacement measurement values of the upper and lower electrode caps from the laser measurement box, and converting the analog signal (the displacement measurement value of the laser measurement box) into a digital signal through an A / D converter.

[0098] The calculation control unit receives the digitized displacement measurements of the upper and lower electrode caps transmitted by the data acquisition card. It processes this data and performs the necessary calculations to determine the actual displacement of the upper and lower electrode caps. Once the calculations are complete, the results are sent to the data recording and display system for easy viewing and recording.

[0099] The power supply module is connected to the data acquisition card and the calculation control unit respectively to ensure that the data acquisition card and the calculation control unit can operate normally.

[0100] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

Claims

1. A robot welding gun electrode cap centering detection device, characterized in that: The centering detection device automatically triggers the measurement and realizes automatic line-edge measurement in conjunction with the motion trajectory setting of the robot welding clamp; the centering detection device includes: A laser measurement box, the data output end of which is electrically connected to the input end of the data acquisition and calculation control unit, includes a first laser displacement sensor t1, a second laser displacement sensor t2, a third laser displacement sensor t3, and a fourth laser displacement sensor t4; is used to measure the displacement of the upper and lower electrode caps and send the measured values to the data acquisition and calculation control unit, wherein the first laser displacement sensor t1 and the second laser displacement sensor t2 form a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 form another group; each group of laser displacement sensors is arranged along the axis direction of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper electrode cap and the lower electrode cap, and the measurement direction of each group of laser displacement sensors is parallel to and aligned with the direction of the other group of laser displacement sensors The measurement directions are exactly orthogonal, and four laser displacement sensors are set on the periphery of the upper and lower electrode caps of the robot welding clamp, using a non-contact measurement method; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in a first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in a second direction, the second direction being orthogonal to the first direction; the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction; the upper and lower electrode caps are always within the measurement range of the corresponding laser displacement sensor, and the first laser displacement sensor t1 is always in a measuring state, automatically determining and starting the measurement process based on the robot's motion trajectory; A data acquisition and calculation control unit, the input end of which is electrically connected to the data output end of the laser measurement box, and the output end of which is electrically connected to the input end of the data recording and display system, for receiving the measurement value of the laser measurement box and performing A / D conversion, calculating the measurement result, and sending the data to the data recording and display system; The data recording and display system has an input terminal electrically connected to the output terminal of the data acquisition and calculation control unit, and is used to display and store measurement results and issue an alarm according to preset standards or requirements.

2. The robot welding clamp electrode cap centering detection device according to claim 1 is characterized in that: The formula for measuring the actual displacement of the upper and lower electrode caps is: ； in, Indicates the relative offset of the upper and lower electrode caps between the current moment and the previous moment, that is, the actual displacement of the upper and lower electrode caps between the current moment and the previous moment; Indicates the displacement change of the first laser displacement sensor t1 between the current moment and the previous moment; Indicates the displacement change of the second laser displacement sensor t2 between the current moment and the previous moment; Indicates the displacement change of the third laser displacement sensor t3 between the current moment and the previous moment; Indicates the displacement change of the fourth laser displacement sensor t4 between the current moment and the previous moment.

3. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: The geometric center of the upper electrode cap is used as the coordinate origin, the measuring direction of the first laser displacement sensor t1 is used as the x-axis, and the measuring direction of the third laser displacement sensor t3 is used as the y-axis; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the y-axis direction.

4. The robot welding clamp electrode cap centering detection device according to claim 3, characterized in that: The first laser displacement sensor t1 is used to measure the distance between its laser emitting end and the upper electrode cap in the x-axis direction, the second laser displacement sensor t2 is used to measure the distance between its laser emitting end and the lower electrode cap in the x-axis direction, the third laser displacement sensor t3 is used to measure the distance between its laser emitting end and the upper electrode cap in the y-axis direction, and the fourth laser displacement sensor t4 is used to measure the distance between its laser emitting end and the lower electrode cap in the y-axis direction.

5. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: The distances between the first laser displacement sensor t1 , the second laser displacement sensor t2 , the third laser displacement sensor t3 and the fourth laser displacement sensor t4 and the welding clamp body are fixed.

6. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: Before the device is used for the first time, manual detection is required to align the positions of the upper and lower electrode caps, that is, initial calibration or zero point calibration.

7. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: The device calculates the actual displacement of the upper and lower electrode caps in real time when in use , until the actual displacement Less than the preset value.

8. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: The first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are infrared laser sensors, and when the four laser displacement sensors are in operation, the upper and lower electrode caps are always located within the measurement range of the corresponding laser displacement sensors.

9. The robot welding clamp electrode cap centering detection device according to claim 1, characterized in that: The data acquisition and calculation control unit includes an acquisition card, a calculation control unit and a power supply module; The input end of the acquisition card is electrically connected to the data output end of the laser measurement box, the output end is electrically connected to the input end of the calculation control unit, and the power supply end is connected to the power supply module; the data acquisition card performs A / D conversion on the measurement value received from the laser measurement box and sends it to the calculation control unit; The input end of the calculation control unit is electrically connected to the output end of the data acquisition card, the output end is electrically connected to the data recording and display system, and the power supply end is connected to the power supply module; the calculation control unit is used to process and calculate the digital signal transmitted by the acquisition card, obtain the relative offset of the upper and lower electrode caps, and send the result to the data recording and display system; The power supply module is connected to the acquisition card and the calculation control unit and supplies power to them.

10. A method for detecting the centering of an electrode cap of a robot welding clamp, characterized in that: The method uses the robot welding clamp electrode cap centering detection device according to claim 1 for detection, and the method includes: After the initial calibration is completed and the centering detection device is powered on, the first laser displacement sensor t1 automatically determines and starts the measurement process based on the robot's motion trajectory; After the first laser displacement sensor t1 starts the measurement process, the laser measurement box inputs the displacement measurement values of the upper and lower electrode caps collected in real time into the data acquisition and calculation control unit, which specifically includes: the first laser displacement sensor t1 and the second laser displacement sensor t2 are a group of laser displacement sensors, and the third laser displacement sensor t3 and the fourth laser displacement sensor t4 are another group; each group of laser displacement sensors is arranged along the axis direction of the upper and lower electrode caps and is respectively aligned with the geometric center of the upper and lower electrode caps, the measurement direction of each group of laser displacement sensors is parallel and exactly orthogonal to the measurement direction of the other group of laser displacement sensors, and the four laser displacement sensors are arranged on the periphery of the upper and lower electrode caps of the robot welding clamp, using a non-contact measurement method; the first laser displacement sensor t1 is used to measure the displacement of the upper electrode cap in a first direction, the second laser displacement sensor t2 is used to measure the displacement of the lower electrode cap in the first direction, and the third laser displacement sensor t3 is used to measure the displacement of the upper electrode cap in a second direction, the second direction being orthogonal to the first direction; the fourth laser displacement sensor t4 is used to measure the displacement of the lower electrode cap in the second direction; The data acquisition and calculation control unit receives the displacement measurement values of the upper and lower electrode caps measured by the laser measurement box in real time, performs A / D conversion, calculates the relative offset of the upper and lower electrode caps between the current moment and the previous moment based on the data measured by the first laser displacement sensor t1, the second laser displacement sensor t2, the third laser displacement sensor t3, and the fourth laser displacement sensor t4, that is, the actual displacement of the upper and lower electrode caps, and sends the actual displacement to the data recording and display system in real time; The data recording and display system displays and stores the actual displacement data of the upper and lower electrode caps sent by the data acquisition and calculation control unit in real time, and issues an alarm according to preset standards or requirements.

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