A welding system and method for the valve body and top cover plate of an explosion-proof valve.

Abstract

This invention relates to the field of explosion-proof valve welding technology, and particularly to a welding system and method for welding the valve body and top cover plate of an explosion-proof valve. The system includes a frame, a main indexing plate mechanism, an explosion-proof valve body pickup, installation, and smoothing mechanism, a welding mechanism, and a magazine mechanism. At the first station, the top cover plate is placed on the main indexing plate mechanism. At the second station, the explosion-proof valve body pickup, installation, and smoothing mechanism picks up the valve body from the magazine mechanism, performs gradual vibration, visual positioning, and angle compensation, and then installs the valve body into the slot of the top cover plate, smoothing the valve body. At the third station, the welding mechanism welds the smoothed explosion-proof valve body to the top cover plate. At the fourth station, the welded product is removed. The system and method provided by this invention provide precise installation and a level surface, improving the welding quality and efficiency of the explosion-proof valve body and top cover plate.

Description

Technical Field

[0001] This invention relates to the field of explosion-proof valve welding technology, and in particular to a welding system and method for welding the valve body and top cover plate of an explosion-proof valve. Background Technology

[0002] With the rapid expansion of the electric vehicle, renewable energy, and energy storage markets, new energy battery technology is becoming a crucial driving force for the green economy. Explosion-proof valves for energy storage and automotive power batteries are a key component that has emerged with the rapid development of energy storage technology and the electric vehicle industry. In battery systems, the reliable operation of explosion-proof valves directly affects the safety of the vehicle and the system. The explosion-proof valve body is made of aluminum alloy, while the top cover is made of stainless steel, and both components are very thin, especially the valve body, which is only 0.1 to 0.3 millimeters thick. Achieving precise welding and assembly of these two metals requires high-precision welding equipment and processes. A prerequisite for the welding effect of explosion-proof valves is the accuracy of the flatness and positioning of the valve body and top cover. Traditional explosion-proof valve welding systems use servo motor positioning systems to place the valve body onto the top cover and then weld it directly. This results in inaccurate valve body installation, low installation efficiency, and uneven valve body, ultimately affecting the welding quality and efficiency between the valve body and the top cover. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a welding system and method for the valve body and top cover plate of an explosion-proof valve. The valve body is installed in a precise position, with high installation efficiency and relatively flat installation, thereby improving the welding quality and welding efficiency between the valve body and the top cover plate of the explosion-proof valve.

[0004] This invention is achieved through the following scheme:

[0005] A welding system for an explosion-proof valve body and a top cover plate includes a frame and a main indexing plate mechanism, an explosion-proof valve body pickup, installation, and smoothing mechanism, a welding mechanism, and a magazine mechanism mounted on the frame. The main indexing plate mechanism is evenly provided with four sets of fixture modules corresponding to the four workstations of the system. At the first workstation of the system, the top cover plate is placed on the fixture module of the main indexing plate mechanism. The explosion-proof valve body pickup, installation, and smoothing mechanism and the magazine mechanism are located at the second workstation of the system. The explosion-proof valve body pickup, installation, and smoothing mechanism is used to pick up the explosion-proof valve body placed in the magazine mechanism and perform gradual vibration to ensure that one explosion-proof valve body is picked up at a time. After visual positioning and angle compensation of the explosion-proof valve body, the explosion-proof valve body is installed in the slot of the top cover plate of the fixture module and the explosion-proof valve body is hard smoothed. The welding mechanism is located at the third workstation of the system and is used to weld the smoothed explosion-proof valve body to the top cover plate. The welded product is removed at the fourth workstation of the system.

[0006] Furthermore, the main indexing plate mechanism includes a main indexing plate and a main indexing plate drive motor. The main indexing plate is driven to rotate by the main indexing plate drive motor. The four sets of fixture modules are evenly arranged on the main indexing plate. Each set of fixture modules is provided with an explosion-proof valve mounting slot, and the explosion-proof valve mounting slot is provided with a vacuum suction hole.

[0007] The optimized design includes two mounting slots for the explosion-proof valve.

[0008] Furthermore, the fixture module is equipped with a negative pressure detection mechanism, which includes a vacuum pump and a negative pressure detection pipeline. The negative pressure detection pipeline is connected between the vacuum pump and the vacuum suction port of the explosion-proof valve mounting slot. A vacuum detection meter and a vacuum filter are installed on the negative pressure detection pipeline. The vacuum detection meter is connected to the PLC through a signal line.

[0009] Furthermore, the magazine mechanism includes a lifting unit, a magazine unit, and a rotating unit. The magazine unit includes a mounting plate and an explosion-proof valve body mounting body fixedly mounted on the mounting plate. The explosion-proof valve body mounting body has a cubic structure, and each cubic side is fixedly provided with two sets of limiting posts. An explosion-proof valve body mounting groove is provided between each set of limiting posts. The rotating unit drives the mounting plate to rotate. The lifting unit includes a lifting drive device, a lifting plate, and lifting rods. The lifting drive device drives the lifting plate to move up and down. The lifting rods are two rods that are respectively horizontally fixedly mounted on the lifting plate, and the ends of the two lifting rods extend into the corresponding explosion-proof valve body mounting grooves.

[0010] The optimized magazine mechanism also includes a material presence / absence detection sensor, which is installed on the top of the explosion-proof valve body mounting body. The material presence / absence detection sensor is connected to the PLC via a signal line, and the PLC controls the operation of the lifting unit, the rotating unit, and the explosion-proof valve body picking, mounting, and leveling mechanism.

[0011] Furthermore, the explosion-proof valve body pickup, installation, and smoothing mechanism includes a first transfer X-axis module, a first transfer Y-axis module, a first transfer Z-axis module, a first rotating R-axis module, a suction nozzle, a Z-phase cylinder, and a vision inspection unit. The first transfer Y-axis module is mounted on the first transfer X-axis module. There are two sets of the first transfer Z-axis module, the first rotating R-axis module, the suction nozzle, and the vision inspection unit. Two first transfer Z-axis modules are mounted on the first transfer Y-axis module. Two first rotating R-axis modules, the Z-phase cylinder, and the vision inspection unit are all mounted on the first transfer Z-axis module. Two suction nozzles are mounted on the first rotating R-axis module. A smoothing plate is fixedly mounted at the end of the connecting rod of the Z-phase cylinder. A conductive carbon nanotube sponge is fixedly mounted on the smoothing plate. A clearance groove is opened in the middle of the conductive carbon nanotube sponge.

[0012] The optimized nozzle is a non-metallic flexible nozzle.

[0013] Furthermore, the welding mechanism includes a welding mechanism column, a second transfer X-axis module, a second transfer Y-axis module, a second transfer Z-axis module, and a pulsed laser welding instrument. The second transfer Y-axis module is fixedly installed on the welding mechanism column. The second transfer X-axis module is installed on the second transfer Y-axis module, and the second transfer Y-axis module drives the second transfer X-axis module to move along the Y-axis. The second transfer Z-axis module is installed on the second transfer X-axis module, and the second transfer X-axis module drives the second transfer Z-axis module to move along the X-axis. The pulsed laser welding instrument is installed on the second transfer Z-axis module, and the second transfer Z-axis module drives the pulsed laser welding instrument to move along the Z-axis.

[0014] A method for welding the valve body and top cover plate of an explosion-proof valve includes the following steps:

[0015] S1: Place the top cover plate in the explosion-proof valve mounting slot of the main indexing plate mechanism. The main indexing plate mechanism drives the top cover plate to move to the explosion-proof valve body pickup, installation and smoothing mechanism.

[0016] S2: The suction nozzle of the explosion-proof valve body picking and installing smoothing mechanism picks up the explosion-proof valve body from the magazine mechanism and performs gradual vibration on the picked-up explosion-proof valve body to ensure that a single piece of explosion-proof valve body is picked up. Then, the explosion-proof valve body is visually positioned, and the rotation angle compensation value is fed back to the PLC. The PLC controls the explosion-proof valve body picking and installing smoothing mechanism to drive the explosion-proof valve body to rotate for angle compensation.

[0017] S3: Place the angle-compensated explosion-proof valve body into the slot of the top cover plate in the explosion-proof valve mounting groove, and press it into place using a Z-phase cylinder with conductive carbon nanotube sponge. Then, perform multi-directional hard smoothing on the explosion-proof valve body.

[0018] S4: Perform negative pressure detection on the explosion-proof valve body and top cover plate, and feed back the negative pressure value to the PLC. The PLC compares the negative pressure value with the set threshold. If the negative pressure value is greater than or equal to the set threshold, it means that the explosion-proof valve body is installed in place and proceeds to the next step. If the negative pressure value is less than the set threshold, it means that the explosion-proof valve body is not installed in place. The explosion-proof valve body is picked up and dropped into the NG box. The main indexing plate mechanism drives the top cover plate to run again to the explosion-proof valve body picking and installation smoothing mechanism to reinstall the explosion-proof valve body.

[0019] S5: The main indexing plate mechanism drives the installed explosion-proof valve body and top cover plate to the welding mechanism for welding operations until welding is completed, thus completing the product assembly.

[0020] Beneficial effects of the invention:

[0021] The present invention provides a welding system and method for the valve body and top cover plate of an explosion-proof valve. The system has a relatively compact structure, and the valve body of the explosion-proof valve is installed in a precise and flat position, which improves the welding quality and welding efficiency of the valve body and the top cover plate of the explosion-proof valve. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the assembly structure of the present invention.

[0023] Figure 2 This is a top view schematic diagram of the main indexing plate mechanism of the present invention.

[0024] Figure 3 This is a schematic diagram of the main indexing plate mechanism of the present invention.

[0025] Figure 4 This is a schematic diagram of the magazine mechanism of the present invention.

[0026] Figure 5 This is a schematic diagram of the valve body mounting structure of the explosion-proof valve of the present invention.

[0027] Figure 6 This is a schematic diagram of the structure of the explosion-proof valve body picking, installation, and smoothing mechanism of the present invention.

[0028] Figure 7 This is a schematic diagram of the welding mechanism structure of the present invention.

[0029] In the diagram: 1. Frame; 2. Main indexing plate mechanism; 21. Main indexing plate; 211. Fixture module; 212. Explosion-proof valve mounting slot; 22. Main indexing plate drive motor; 3. Explosion-proof valve body picking, mounting, and smoothing mechanism; 31. First transfer Y-axis module; 32. First transfer X-axis module; 33. First transfer Z-axis module; 34. First rotary R-axis module; 35. Nozzle; 36. Z-phase cylinder; 37. Conductive carbon nanotube sponge; 38. Smoothing plate; 39. Vision inspection unit; 4. Magazine mechanism; 41. Lifting unit; 411. Lifting drive device; 41 2. Lifting plate; 413. Lifting rod; 42. Magazine unit; 421. Mounting plate; 422. Explosion-proof valve body mounting body; 423. Limiting post; 424. Explosion-proof valve body mounting groove; 43. Rotation unit; 44. Material presence / absence detection sensor; 5. Welding mechanism; 51. Second transfer Y-axis module; 52. Second transfer X-axis module; 53. Second transfer Z-axis module; 54. Pulsed laser welding instrument; 55. Welding mechanism column; 6. Negative pressure detection mechanism; 61. Vacuum suction port; 62. Vacuum filter; 63. Vacuum pump; 64. Vacuum detection gauge. Detailed Implementation

[0030] A schematic diagram of the assembly structure of a welding system for the valve body and top cover of an explosion-proof valve is shown below. Figure 1As shown, the system includes a frame 1 and a main indexing plate mechanism 2, an explosion-proof valve body picking, mounting, and smoothing mechanism 3, a welding mechanism 5, and a magazine mechanism 4 mounted on the frame. The main indexing plate mechanism is evenly provided with four sets of fixture modules corresponding to the four workstations of the system. At the first workstation of the system, the top cover is placed on the fixture module of the main indexing plate mechanism. The explosion-proof valve body picking, mounting, and smoothing mechanism and the magazine mechanism are located at the second workstation of the system. The explosion-proof valve body picking, mounting, and smoothing mechanism is used to pick up the explosion-proof valve body placed in the magazine mechanism and perform gradual vibration to ensure that one explosion-proof valve body is picked up at a time. After visual positioning and angle compensation of the explosion-proof valve body, the explosion-proof valve body is installed in the slot of the top cover of the fixture module and the explosion-proof valve body is hard smoothed. The welding mechanism is located at the third workstation of the system and is used to weld the smoothed explosion-proof valve body to the top cover. The welded product is taken away at the fourth workstation of the system.

[0031] The main indexing plate mechanism is evenly equipped with four sets of fixture modules corresponding to the four workstations of the system. In this way, the four workstations surround the main indexing plate mechanism and can work simultaneously, resulting in high production efficiency.

[0032] The explosion-proof valve body pickup and installation smoothing mechanism picks up the valve body placed in the magazine mechanism and then applies gradual vibration. Specifically, the vibration amplitude can be parabolic, with the difference between the initial amplitude, the stop amplitude, and the peak amplitude being approximately 2 mm. The vibration frequency is 3 times per cycle. This can overcome the critical displacement of static friction, thereby effectively eliminating the electrostatic adsorption of the explosion-proof valve body and ensuring that the nozzle picks up only one explosion-proof valve body at a time and installs it into the slot of the top cover plate of the fixture module.

[0033] Visual positioning and angle compensation of the explosion-proof valve body can ensure that the installation position of the explosion-proof valve body is relatively accurate.

[0034] Hardening the valve body of the explosion-proof valve can ensure its flatness, thereby ensuring the contact area between the valve body and the top cover plate, and thus ensuring the welding quality of the valve body and the top cover plate.

[0035] Furthermore, the schematic diagram of the main indexing plate mechanism is as follows: Figure 2 , Figure 3 As shown, it includes a main indexing plate 21 and a main indexing plate drive motor 22. The main indexing plate is driven to rotate by the main indexing plate drive motor. Four sets of fixture modules 211 are evenly arranged on the main indexing plate. Each set of fixture modules is provided with an explosion-proof valve mounting slot 212. The explosion-proof valve mounting slot is provided with a vacuum suction hole 61. The explosion-proof valve mounting slot is used to place the top cover plate and the explosion-proof valve body.

[0036] The main indexing plate drive motor drives the main indexing plate to rotate, so that the fixture module can move to the corresponding workstation.

[0037] The optimized design features two explosion-proof valve mounting slots, allowing two explosion-proof valves to be moved and assembled simultaneously during one revolution of the main indexing plate mechanism, further improving production efficiency.

[0038] Furthermore, the fixture module is equipped with a negative pressure detection mechanism 6, which includes a vacuum pump 63 and a negative pressure detection pipeline (not shown). The negative pressure detection pipeline is connected between the vacuum pump and the vacuum suction port of the explosion-proof valve mounting slot. A vacuum detection meter 64 and a vacuum filter 62 are installed on the negative pressure detection pipeline. The vacuum detection meter is connected to the PLC through a signal line.

[0039] After the explosion-proof valve body is installed and hardened, a negative pressure test can be performed. After the negative pressure device passes the test, the main indexing plate mechanism will then transfer the installed explosion-proof valve body and top cover to the next work station.

[0040] Specifically, the negative pressure can be detected by a vacuum detector and fed back to the PLC. The PLC compares the negative pressure with a set threshold. If the negative pressure is greater than or equal to the set threshold, it means that the explosion-proof valve body is installed correctly and proceeds to the next station. If the negative pressure is less than the set threshold, it means that the explosion-proof valve body is not installed correctly. In this case, the explosion-proof valve body is picked up and dropped into the NG box. The main indexing plate mechanism then drives the top cover plate to run back to the explosion-proof valve body picking, installation, and smoothing mechanism to reinstall the explosion-proof valve body.

[0041] Installing a vacuum filter can prevent dust and other contaminants from entering, further ensuring the quality of the explosion-proof valve.

[0042] Furthermore, a schematic diagram of the magazine mechanism is shown below. Figure 4 As shown, it includes a lifting unit 41, a magazine unit 42, and a rotating unit 43. The magazine unit includes a mounting plate 421 and an explosion-proof valve body mounting body 422 fixedly mounted on the mounting plate. A schematic diagram of the explosion-proof valve body mounting body is shown below. Figure 5 As shown, it has a cubic structure, and each cubic side is fixed with two sets of limiting posts 423. An explosion-proof valve body mounting groove 424 is provided between each set of limiting posts. The rotating unit drives the mounting plate to rotate. The lifting unit includes a lifting drive device 411, a lifting plate 412 and a lifting rod 413. The lifting drive device drives the lifting plate to move up and down. The lifting rod consists of two rods that are horizontally fixed on the lifting plate. The ends of the two lifting rods extend into the corresponding explosion-proof valve body mounting grooves.

[0043] Each explosion-proof valve body mounting slot can hold a stack of explosion-proof valve bodies. When it is necessary to pick up the explosion-proof valve body, the lifting drive device drives the lifting plate to move upward, so that the lifting rod reaches the position of the explosion-proof valve body mounting slot. As the lifting plate continues to move upward, the two lifting rods simultaneously lift the two stacks of explosion-proof valve bodies to the corresponding positions. The explosion-proof valve body picking, installation and smoothing mechanism can then pick up the top two explosion-proof valve bodies at the same time.

[0044] The optimized magazine mechanism also includes a material presence / absence detection sensor 44, which is installed on the top of the explosion-proof valve body mounting body. The material presence / absence detection sensor is connected to the PLC via a signal line, and the PLC controls the operation of the lifting unit, the rotating unit, and the explosion-proof valve body picking, mounting, and leveling mechanism.

[0045] When the material presence sensor detects the presence of the explosion-proof valve body, the PLC controls the lifting unit to stop operating and controls the explosion-proof valve body pickup and installation leveling mechanism to pick up the valve body. If the material presence sensor still does not detect the explosion-proof valve body when the lifting unit reaches the top, it indicates that there is no explosion-proof valve body in the valve body mounting slot. In this case, the PLC controls the rotating unit to operate, driving the magazine unit to rotate so that the explosion-proof valve body mounting slot on the other side of the valve body mounting body aligns with the lifting rod, thus achieving normal material feeding.

[0046] Furthermore, a schematic diagram of the explosion-proof valve body pickup, installation, and smoothing mechanism is shown below. Figure 6 As shown, it includes a first transplanting X-axis module 32, a first transplanting Y-axis module 31, a first transplanting Z-axis module 33, a first rotating R-axis module 34, a suction nozzle 35, a Z-phase cylinder 36, and a vision inspection unit 39. The first transplanting Y-axis module is mounted on the first transplanting X-axis module. There are two sets of the first transplanting Z-axis module, the first rotating R-axis module, the suction nozzle, the Z-phase cylinder, and the vision inspection unit. The first transplanting Z-axis module is mounted on the first transplanting Y-axis module. The first rotating R-axis module, the Z-phase cylinder, and the vision inspection unit are mounted on the first transplanting Z-axis module. The suction nozzle is mounted on the first rotating R-axis module. A smoothing plate 38 is fixedly mounted on the end of the connecting rod of the Z-phase cylinder. A conductive carbon nanotube sponge 37 is fixedly mounted on the smoothing plate. A clearance groove is opened in the middle of the conductive carbon nanotube sponge.

[0047] The first transfer X-axis module, the first transfer Y-axis module, and the first transfer Z-axis module control the suction nozzle to move along the X, Y, and Z axes, respectively, to simultaneously pick up the two explosion-proof valve bodies lifted by the lifting unit. By controlling the first transfer X-axis module and the first transfer Y-axis module to reciprocate within a set range, the explosion-proof valve body can be made to vibrate gradually, ensuring the pickup of a single explosion-proof valve body. Then, the vision inspection unit performs visual positioning detection on the explosion-proof valve body and feeds back the rotation angle compensation value to the PLC. The PLC controls the first rotation... After the R-axis module rotates the explosion-proof valve body for angle compensation, the valve body is placed into the slot of the top cover plate in the explosion-proof valve mounting groove. The Z-phase cylinder connecting rod moves downward, pressing the explosion-proof valve body down through the conductive carbon nanotube sponge and holding the pressure for a period of time to eliminate residual stress. The duration is about 1 second. Then, under the sequential positioning control of the first transfer X-axis module and the first transfer Y-axis module, the explosion-proof valve body is subjected to a hard-smoothing action in the forward, backward, left and right directions to ensure the flatness of the explosion-proof valve body. After the negative pressure test is qualified, it enters the next station.

[0048] Setting up a Z-phase cylinder can simultaneously smooth the valve bodies of two explosion-proof valves. The addition of conductive carbon nanotube sponge helps to eliminate residual stress in the explosion-proof valve body and smooth it out, while also preventing damage to the valve body during the hard smoothing process.

[0049] The optimized nozzle is a non-metallic flexible nozzle. The use of a non-metallic flexible nozzle can reduce poor adhesion caused by uneven product surface height and electrostatic discharge phenomenon of explosion-proof valve body.

[0050] Furthermore, the schematic diagram of the welding mechanism is as follows: Figure 7 As shown, the assembly includes a welding mechanism column 55, a second transfer X-axis module 52, a second transfer Y-axis module 51, a second transfer Z-axis module 53, and a pulsed laser welding instrument 54. The second transfer Y-axis module is fixedly installed on the welding mechanism column. The second transfer X-axis module is installed on the second transfer Y-axis module and drives the second transfer X-axis module to move along the Y-axis. The second transfer Z-axis module is installed on the second transfer X-axis module and drives the second transfer Z-axis module to move along the X-axis. The pulsed laser welding instrument is installed on the second transfer Z-axis module and drives the pulsed laser welding instrument to move along the Z-axis.

[0051] The second transfer X-axis module, the second transfer Y-axis module, and the second transfer Z-axis module can drive the pulsed laser welding machine to run along the X-axis, Y-axis, and Z-axis to perform all-round welding on the explosion-proof valve body and top cover plate.

[0052] The pulsed laser welding machine uses pulsed lasers to perform symmetrical spot welding at planned locations. The energy per spot is 5 to 10 joules, and the laser power is adjustable. The number of spot welds is determined by the thermal deformation of the explosion-proof valve body and top cover plate. The preferred number of spot welds is four, arranged symmetrically in a cross shape. Then, continuous laser welding is used to fill the gaps along the spot welding trajectory. The welding power is 20-30 times that of the spot welding energy, and the scanning path includes at least one overlapping weld. The laser welding machine communicates with a PLC, featuring high communication speed and intuitive and convenient signal monitoring.

[0053] A method for welding the valve body and top cover plate of an explosion-proof valve includes the following steps:

[0054] S1: Place the top cover plate in the explosion-proof valve mounting slot of the main indexing plate mechanism. The main indexing plate mechanism drives the top cover plate to move to the explosion-proof valve body pickup, installation and smoothing mechanism.

[0055] S2: The suction nozzle of the explosion-proof valve body picking and installing smoothing mechanism picks up the explosion-proof valve body from the magazine mechanism and performs gradual vibration on the picked-up explosion-proof valve body to ensure that a single piece of explosion-proof valve body is picked up. Then, the explosion-proof valve body is visually positioned, and the rotation angle compensation value is fed back to the PLC. The PLC controls the explosion-proof valve body picking and installing smoothing mechanism to drive the explosion-proof valve body to rotate for angle compensation.

[0056] S3: Place the angle-compensated explosion-proof valve body into the slot of the top cover plate in the explosion-proof valve mounting groove, and press it into place using a Z-phase cylinder with conductive carbon nanotube sponge. Then, perform multi-directional hard smoothing on the explosion-proof valve body.

[0057] S4: Perform negative pressure detection on the explosion-proof valve body and top cover plate, and feed back the negative pressure value to the PLC. The PLC compares the negative pressure value with the set threshold. If the negative pressure value is greater than or equal to the set threshold, it means that the explosion-proof valve body is installed in place and proceeds to the next step. If the negative pressure value is less than the set threshold, it means that the explosion-proof valve body is not installed in place. The explosion-proof valve body is picked up and dropped into the NG box. The main indexing plate mechanism drives the top cover plate to run again to the explosion-proof valve body picking and installation smoothing mechanism to reinstall the explosion-proof valve body.

[0058] S5: The main indexing plate mechanism drives the installed explosion-proof valve body and top cover plate to the welding mechanism for welding operations until welding is completed, thus completing the product assembly.

[0059] Helium testing was conducted on products welded using the system and method provided by this invention. The results showed that the airtightness was improved by 1000 times compared to products produced using traditional methods, significantly enhancing product stability. Furthermore, welding deformation, weld strength, and production efficiency were all greatly improved. Specific test results are shown in Table 1.

[0060] Table 1

[0061]

[0062] In summary, the explosion-proof valve body and top cover plate welding system and method proposed in this invention have a relatively compact system structure, the explosion-proof valve body is installed in a precise and flat position, and the welding quality and welding efficiency of the explosion-proof valve body and top cover plate are significantly improved.

[0063] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A welding system for the valve body and top cover plate of an explosion-proof valve, characterized in that: The system includes a frame and a main indexing plate mechanism mounted on the frame, an explosion-proof valve body pickup, installation, and smoothing mechanism, a welding mechanism, and a magazine mechanism. The main indexing plate mechanism has four sets of fixture modules evenly distributed to correspond to the four workstations of the system. At the first workstation, the top cover is placed on the fixture module of the main indexing plate mechanism. The explosion-proof valve body pickup, installation, and smoothing mechanism and the magazine mechanism are located at the second workstation. The explosion-proof valve body pickup, installation, and smoothing mechanism includes a first transfer X-axis module, a first transfer Y-axis module, a first transfer Z-axis module, a first rotary R-axis module, a nozzle, a Z-phase cylinder, and a vision inspection unit. The first transfer Y-axis module is mounted on the first transfer X-axis module. There are two sets of the first transfer Z-axis module, the first rotary R-axis module, the nozzle, and the vision inspection unit. Two sets of the first transfer Z-axis modules are mounted on the first transfer Y-axis module. The first rotating R-axis module, Z-phase cylinder, and vision inspection unit are all mounted on the first transfer Z-axis module. The two suction nozzles are mounted on the first rotating R-axis module. A smoothing plate is fixedly mounted on the end of the connecting rod of the Z-phase cylinder. A conductive carbon nanotube sponge is fixedly mounted on the smoothing plate. A clearance groove is opened in the middle of the conductive carbon nanotube sponge. The explosion-proof valve body picking and smoothing mechanism is used to pick up the explosion-proof valve body placed in the magazine mechanism and perform gradual vibration to ensure that one explosion-proof valve body is picked up at a time. After visual positioning and angle compensation of the explosion-proof valve body, the explosion-proof valve body is installed in the slot of the top cover plate in the fixture module and the explosion-proof valve body is hard smoothed. The welding mechanism is set at the third station of the system and is used to weld the smoothed explosion-proof valve body to the top cover plate. The welded product is taken away at the fourth station of the system.

2. The explosion-proof valve body and top cover welding system according to claim 1, characterized in that: The main indexing plate mechanism includes a main indexing plate and a main indexing plate drive motor. The main indexing plate is driven to rotate by the main indexing plate drive motor. Four sets of fixture modules are evenly arranged on the main indexing plate. Each set of fixture modules is provided with an explosion-proof valve mounting slot, and the explosion-proof valve mounting slot is provided with a vacuum suction hole.

3. The explosion-proof valve body and top cover welding system according to claim 2, characterized in that: There are two mounting slots for the explosion-proof valve.

4. The explosion-proof valve body and top cover welding system according to claim 2, characterized in that: Each fixture module is equipped with a negative pressure detection mechanism, which includes a vacuum pump and a negative pressure detection pipeline. The negative pressure detection pipeline is connected between the vacuum pump and the vacuum suction port of the explosion-proof valve mounting slot. A vacuum detection meter and a vacuum filter are installed on the negative pressure detection pipeline. The vacuum detection meter is connected to the PLC through a signal line.

5. The explosion-proof valve body and top cover welding system according to claim 1, characterized in that: The magazine mechanism includes a lifting unit, a magazine unit, and a rotating unit. The magazine unit includes a mounting plate and an explosion-proof valve body mounting body fixedly mounted on the mounting plate. The explosion-proof valve body mounting body has a cubic structure, and each cubic side is fixedly provided with two sets of limiting posts. An explosion-proof valve body mounting groove is provided between each set of limiting posts. The rotating unit drives the mounting plate to rotate. The lifting unit includes a lifting drive device, a lifting plate, and lifting rods. The lifting drive device drives the lifting plate to move up and down. The lifting rods are two rods that are respectively horizontally fixedly mounted on the lifting plate, and the ends of the two lifting rods extend into the corresponding explosion-proof valve body mounting grooves.

6. The explosion-proof valve body and top cover welding system according to claim 5, characterized in that: The magazine mechanism also includes a material presence or absence detection sensor, which is installed on the top of the explosion-proof valve body mounting body. The material presence or absence detection sensor is connected to the PLC via a signal line, and the PLC controls the operation of the lifting unit, the rotating unit, and the explosion-proof valve body picking, mounting, and leveling mechanism.

7. The explosion-proof valve body and top cover welding system according to claim 1, characterized in that: The suction nozzle is a non-metallic flexible suction nozzle.

8. The explosion-proof valve body and top cover welding system according to claim 1, characterized in that: The welding mechanism includes a welding mechanism column, a second transfer X-axis module, a second transfer Y-axis module, a second transfer Z-axis module, and a pulsed laser welding instrument. The second transfer Y-axis module is fixedly installed on the welding mechanism column. The second transfer X-axis module is installed on the second transfer Y-axis module and drives the second transfer X-axis module to move along the Y-axis. The second transfer Z-axis module is installed on the second transfer X-axis module and drives the second transfer Z-axis module to move along the X-axis. The pulsed laser welding instrument is installed on the second transfer Z-axis module and drives the pulsed laser welding instrument to move along the Z-axis.

9. A method for welding the valve body and top cover plate of an explosion-proof valve, implemented by a welding system for the valve body and top cover plate of an explosion-proof valve as described in any one of claims 1 to 8, characterized in that: Includes the following steps: S1: Place the top cover plate in the explosion-proof valve mounting slot of the main indexing plate mechanism. The main indexing plate mechanism drives the top cover plate to move to the explosion-proof valve body pickup, installation and smoothing mechanism. S2: The suction nozzle of the explosion-proof valve body picking and installing smoothing mechanism picks up the explosion-proof valve body from the magazine mechanism and performs gradual vibration on the picked-up explosion-proof valve body to ensure that a single piece of explosion-proof valve body is picked up. Then, the explosion-proof valve body is visually positioned, and the rotation angle compensation value is fed back to the PLC. The PLC controls the explosion-proof valve body picking and installing smoothing mechanism to drive the explosion-proof valve body to rotate for angle compensation. S3: Place the angle-compensated explosion-proof valve body into the slot of the top cover plate in the explosion-proof valve mounting groove, and press it into place using a Z-phase cylinder with conductive carbon nanotube sponge. Then, perform multi-directional hard smoothing on the explosion-proof valve body. S4: Perform negative pressure detection on the explosion-proof valve body and top cover plate, and feed back the negative pressure value to the PLC. The PLC compares the negative pressure value with the set threshold. If the negative pressure value is greater than or equal to the set threshold, it means that the explosion-proof valve body is installed in place and proceeds to the next step. If the negative pressure value is less than the set threshold, it means that the explosion-proof valve body is not installed in place. The explosion-proof valve body is picked up and dropped into the NG box. The main indexing plate mechanism drives the top cover plate to run again to the explosion-proof valve body picking and installation smoothing mechanism to reinstall the explosion-proof valve body. S5: The main indexing plate mechanism drives the installed explosion-proof valve body and top cover plate to the welding mechanism for welding operations until welding is completed, thus completing the product assembly.

Images