High-quality copper casting welding device for connecting parts

Abstract

The invention relates to the technical field of welding devices, in particular to a high-quality copper casting welding device for connecting parts. Comprising a base frame, a microcontroller, a vibration pressing frame and a pressure supplementing frame, a transmission shaft driven by a servo motor is rotationally installed on the base frame, a cradle is rotationally installed in the middle of the base frame, two shaping arms with the adjustable distance are installed on the cradle, and two outer shaping wheels are rotationally installed on each shaping arm; a reciprocating shaking system, a variable-stroke driving system and a position-adjustable welding frame are arranged on the base frame, when the transmission shaft rotates, the reciprocating shaking system drives the cradle to shake in a reciprocating manner within + / -35 degrees, and a guide frame is mounted on the variable-stroke driving system. The method has the beneficial effects that through internal and external cooperative dynamic shaping, intelligent closed-loop parameter adjustment, composite vibration pressure application and multi-system automatic linkage, real-time correction of thermal deformation in the copper casting welding process is achieved, and welding defects are effectively eliminated.

Description

Technical Field

[0001] The invention relates to the technical field of welding devices, in particular to a high-quality copper casting welding device for connecting parts. Background Art

[0002] Copper castings are widely used for connecting parts in high-end equipment such as aerospace, precision instruments, and rail transit due to their excellent electrical and thermal conductivity and mechanical properties. The quality of their welding directly affects the operational reliability and service life of the entire equipment. However, the welding process of copper and copper alloys presents many technical difficulties. Existing welding equipment still faces the following prominent issues when achieving high-quality copper casting connections: 1. Copper has a high thermal conductivity. The rapid diffusion of heat during welding leads to a large temperature gradient in the molten pool, which can easily cause local overheating or uneven cooling, leading to warping and shrinkage of the weld and heat-affected zone. Traditional welding equipment lacks a targeted dynamic shaping mechanism and relies solely on static shaping after welding. This not only makes it difficult to correct dimensional deviations caused by thermal deformation, but can also cause weld cracking due to secondary stress concentration. 2. Existing welding devices mostly use fixed process parameters and cannot respond to dynamic changes in the welding process in real time. When welding copper castings, the molten pool state, joint gap, misalignment, etc. will change dynamically with the welding process. Fixed parameters are prone to defects such as incomplete welding, porosity, and slag inclusion. 3. Existing copper casting welding shaping methods mostly use unilateral static pressure, which is difficult to cope with dynamic deformation during welding. The outer side shaping easily ignores the inner weld bulge, and the inner support cannot correct the outer concavity, resulting in local bulges and excessive ovality in the workpiece after welding. 4. The traditional welding process is highly dependent on operator experience. Weld positioning, parameter adjustment, quality inspection and other links are mostly manual intervention, resulting in problems such as delayed response, insufficient accuracy and large quality fluctuations. Based on this, the present invention provides a high-quality copper casting welding device for connecting parts to solve the problems raised in the above background technology. Summary of the Invention

[0003] The present invention realizes real-time correction of thermal deformation during the welding process of copper castings and effective elimination of welding defects through internal and external coordinated dynamic shaping, intelligent closed-loop parameter adjustment, composite vibration pressure and multi-system automated linkage.

[0004] The technical solution of the present invention to solve the above technical problems is as follows: a high-quality copper casting welding device for connecting parts, comprising a base frame, a microcontroller, a vibration and pressure frame and a compensating pressure frame, a transmission shaft driven by a servo motor is rotatably installed on the base frame, a cradle is rotatably installed in the middle of the base frame, two shaping arms with adjustable spacing are installed on the cradle, and two outer shaping wheels are rotatably installed on each shaping arm, a reciprocating shaking system, a variable stroke drive system and a position-adjustable welding frame are provided on the base frame, when the transmission shaft rotates, the reciprocating shaking system drives the cradle to shake back and forth within ±35°, a guide frame is installed on the variable stroke drive system, the guide frame is slidably connected to the vibration and pressure frame and a group of spring followers are installed between the two, a micro-vibration frame that can vibrate horizontally is slidably installed on the vibration and pressure frame, and the micro-vibration frame A return spring is installed between the frame and the vibration and pressure frame, a vibration motor is installed on the micro-vibration frame, a group of elastic pressure parts are installed between the micro-vibration frame and the pressure-compensating frame, and a rotating clamp driven by a transmission shaft is installed on the pressure-compensating frame and the welding frame. A welding robot is provided on the base frame, and the execution end of the welding robot is installed with a welding gun and a first visual probe connected to the microcontroller for communication. A second visual probe and an infrared temperature measuring probe connected to the microcontroller for communication are installed in the middle of the base frame. The microcontroller dynamically adjusts the vibration stroke and vibration frequency of the vibration and pressure frame and the micro-vibration frame in real time according to the data feedback from the first visual probe, the second visual probe and the infrared temperature measuring probe. A shaping system is provided on the base frame, and four inner shaping wheels that can revolve and rotate synchronously are installed on the shaping system and rotate corresponding to the position of the outer shaping wheel.

[0005] The beneficial effects of the present invention are: 1. The present invention designs a collaborative working mechanism of the inner and outer double shaping systems. The outer side drives the cradle to swing back and forth within ±35° through the reciprocating shaking system, driving the outer shaping wheel on the shaping arm to dynamically apply pressure to the outer side of the weld. The inner shaping system drives the rotating frame to rotate through the transmission shaft, so that the four inner shaping wheels revolve synchronously. At the same time, the spacing between the expansion seats is adjusted with the help of the third screw, and the radial position of the inner shaping wheel is accurately adjusted through the connecting rod, forming a three-dimensional shaping effect of outward swing and inward rotation. Combined with the dynamic temperature control of the electric heater integrated in the shaping arm, real-time hot shaping during the welding process is realized, replacing the traditional static shaping mode after welding, effectively dispersing welding residual stress, avoiding weld cracking caused by secondary stress concentration, and controlling the flatness error and ovality deviation to an extremely low range, significantly improving dimensional accuracy.

[0006] 2. The present invention constructs a closed-loop control system for perception, analysis, and regulation. The first visual probe monitors the molten pool morphology and weld deviation in real time, the second visual probe captures the misalignment and gap changes, and the infrared temperature probe tracks the temperature field distribution. All data are transmitted to the microcontroller in real time. The microcontroller dynamically adjusts the vibration stroke of the variable-range drive system and the vibration frequency of the micro-vibration frame based on feedback, so that the welding pressure, vibration parameters, and temperature field always adapt to dynamic welding requirements. This mechanism effectively solves defects such as incomplete penetration, porosity, and slag inclusion caused by fixed parameters, and improves the welding qualification rate.

[0007] 3. The present invention designs a composite vibration pressure system. The vibration pressure frame performs variable-stroke reciprocating vibration along the axis of the copper casting pipe to promote uniform filling of the molten pool. The micro-vibration frame performs high-frequency micro-vibration along the vertical axis to optimize the surface height and roughness of the weld. The two form flexible force transmission through spring followers and elastic pressure members, and cooperate with the pressure compensation frame to achieve dynamic pressure compensation. This composite vibration not only enhances the heat exchange efficiency and assists in heat dissipation, but also corrects the misalignment through bidirectional mechanical action. Cooperating with the synchronous rotation of the rotating fixture, it achieves uniform pressure and shaping throughout the circumferential seam welding process, solves the problems of local bulging and dimensional deviation caused by traditional unilateral shaping, and meets the requirements of high-precision assembly.

[0008] 4. The present invention realizes full-process automated control through the intelligent linkage of multiple systems. The servo motor drives the transmission shaft to synchronously link the reciprocating shaking system, the shaping system and the rotating fixture to ensure the precise coordination of the swing of the outer shaping wheel, the revolution of the inner shaping wheel and the rotation of the copper cast pipe. The microcontroller integrates visual inspection, temperature monitoring and vibration sensor data to automatically adjust the key process factors such as the welding robot's welding gun position, shaping arm spacing, and vibration parameters. From weld positioning and parameter adjustment to quality inspection, no human intervention is required, eliminating quality fluctuations caused by human experience, achieving high consistency and high stability in the welding process, and greatly improving production efficiency and product reliability.

[0009] On the basis of the above technical solution, the present invention can also be improved as follows.

[0010] As a preferred technical solution of the present invention, the reciprocating rocking system includes two rocking shafts rotatably connected to the base frame and an internal gear fixedly mounted on the transmission shaft. The two rocking shafts are respectively arranged on both sides of the transmission shaft. Both rocking shafts are equipped with external gears and toothless gears. Both of the external gears are transmission-connected to the internal gear. A half-toothed ring gear is installed on the rocking frame. The toothless gear is fixedly provided with a transmission tooth segment meshing with the half-toothed ring gear. The center angle corresponding to the effective meshing area on the transmission tooth segment is 160°, and the transmission tooth segments on the two toothless gears are staggered by 180°.

[0011] As a preferred technical solution of the present invention, the variable stroke drive system includes a first linear transmission module installed on the base frame, the first linear transmission module is transmission-mounted with a variable range frame, the variable range frame is slidingly connected to the base frame, a driving shaft driven by a driving motor is rotatably installed on the base frame, a hollow shaft driven by the driving shaft is rotatably installed on the variable range frame, a semicircular trapezoidal table is installed on the hollow shaft, a transmission inclined plate transmission-connected to the semicircular trapezoidal table is installed on the guide frame, the vibration pressure frame is slidingly connected to the base frame and a group of return springs limited by the base frame are installed on the vibration pressure frame.

[0012] As a preferred technical solution of the present invention, the circumferential coverage angle of the semicircular trapezoidal cone is 180°, the axial cross-section of the semicircular trapezoidal cone is an isosceles trapezoidal structure, the angle between the hypotenuse on both sides and the axis is 20°, the ratio of the large end radius to the small end radius of the semicircular trapezoidal cone is 3:1, and the surfaces of the transmission inclined plate and the semicircular trapezoidal cone are provided with anti-slip transmission patterns.

[0013] As a preferred technical solution of the present invention, the microcontroller is fixedly mounted on the base frame, and a first screw rod is rotatably mounted on the cradle. A first positive thread segment and a first negative thread segment are symmetrically arranged on the first screw rod. The first positive thread segment and the first negative thread segment are respectively connected to the two shaping arms in a transmission manner. Electric heaters are integrated on the two shaping arms, and the two shaping arms are slidably connected to the cradle.

[0014] As a preferred technical solution of the present invention, the welding frame is slidably connected to the base frame, and a second linear transmission module is installed on the base frame, and the second linear transmission module is transmission-connected to the welding frame. The two rotating fixtures are clamped with copper cast pipes to be welded, and a ring seam to be welded is provided between the two copper cast pipes to be welded. The data ends of the second visual probe and the infrared temperature probe are both facing the ring seam to be welded, and the inner shaping wheel and the outer shaping wheel both correspond to the position of the ring seam to be welded. The reciprocating displacement direction of the vibration frame is parallel to the axis of the copper cast pipe to be welded, and the reciprocating displacement direction of the micro-vibration frame is perpendicular to the axis of the copper cast pipe to be welded.

[0015] As a preferred technical solution of the present invention, the rotating fixture includes a rotating frame and a hollow shaft, the rotating frame and the hollow shaft in the rotating fixture on the pressure-compensating frame are rotatably installed on the pressure-compensating frame, the rotating frame and the hollow shaft in the rotating fixture on the welding frame are rotatably installed on the welding frame, the hollow shaft is linked to the transmission shaft, a transmission gear is installed on the hollow shaft, a passive gear ring meshing with the transmission gear is installed on the rotating frame, a second screw rod is rotatably installed on the rotating frame, a second positive thread segment and a second reverse thread segment are symmetrically provided on the second screw rod, the second positive thread segment and the second reverse thread segment are both transmission-connected with a clamp for clamping the copper cast pipe to be welded, and the clamp is fixedly provided with an arc-shaped clamping portion that cooperates with the copper cast pipe to be welded.

[0016] As a preferred technical solution of the present invention, the interior of the hollow shaft is fixed with a first through groove with openings at both ends and slidingly connected to the drive shaft, and the interior of the hollow shaft is fixed with a second through groove with openings at both ends and slidingly connected to the transmission shaft, and the cross-sections of the first through groove, the second through groove, the transmission shaft and the drive shaft are all regular hexagons.

[0017] As an optimal technical solution of the present invention, the shaping system includes four shaping platforms, a rotating frame rotatably connected to the base frame and a pulley fixedly mounted on the transmission shaft, the pulley is connected to a synchronous toothed belt for transmission, the rotating frame is connected to the synchronous toothed belt for transmission, a third screw rod is rotatably mounted on the rotating frame, a third positive thread segment and a third negative thread segment are symmetrically arranged on the third screw rod, and an expansion support seat is transmission-mounted on the third positive thread segment and the third negative thread segment, and each shaping platform has two connecting rods hinged on the bottom surface, and the other ends of the two connecting rods are respectively hinged to the two expansion supports, and a bar hole matching the connecting rod is opened on the rotating frame and at the position corresponding to each shaping platform, and the four inner shaping wheels are rotatably mounted on the four shaping platforms.

[0018] As a preferred technical solution of the present invention, the first screw rod, the second screw rod and the third screw rod are all equipped with drive buttons, the micro-vibration frame is equipped with a three-axis acceleration sensor, the data end of the three-axis acceleration sensor is connected to the microcontroller data, and the servo motor and the drive motor are both equipped with encoders connected to the microcontroller data. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 The figure is a schematic diagram of the overall structure of a high-quality copper casting welding device for connecting parts; Figure 2 It is a structural diagram of the vibration motor and the elastic pressure member; Figure 3 Schematic diagram of the structure of the second screw rod and the clamp; Figure 4 It is a schematic diagram of the structure of the cradle and the second visual probe; Figure 5 for Figure 4 Schematic diagram of the local enlarged structure at A in the middle; Figure 6 It is a structural diagram of the cradle and the outer shaping wheel; Figure 7 Schematic diagram of the structure of the third screw rod and the transmission shaft; Figure 8 for Figure 7 Schematic diagram of the local enlarged structure at B in the middle; Figure 9 It is a schematic diagram of the cross-sectional structure of the rotating frame and the expansion support seat; Figure 10 It is a structural diagram of a semicircular trapezoidal cone and a return spring; Figure 11 This is a structural diagram of the welding robot; Figure 12 Schematic diagram of the exploded structure of the drive shaft and guide frame.

[0020] In the accompanying drawings, the components represented by the reference numerals are as follows: 1. Base frame; 2. Microcontroller; 3. Vibration frame; 4. Compensation frame; 5. Servo motor; 6. Drive shaft; 7. Cradle; 8. Shaping arm; 9. External shaping wheel; 10. Welding frame; 11. Guide frame; 12. Spring follower; 13. Micro-vibration frame; 14. Return spring; 15. Vibration motor; 16. Elastic pressure member; 17. Welding robot; 18. Welding gun; 19. First vision probe; 20. Second vision probe; 21. Infrared temperature probe; 22. Internal shaping wheel; 23. Rocking shaft; 24. Internal gear; 25. External gear; 26. Toothless gear; 27. Semi-automatic Gear ring; 28. First linear transmission module; 29. ​​Range change frame; 30. Drive shaft; 31. Hollow shaft; 32. Semicircular trapezoidal table; 33. Transmission ramp; 34. Return spring; 35. First screw; 36. Electric heater; 37. Second linear transmission module; 38. Copper cast pipe to be welded; 39. Rotary frame; 40. Hollow shaft; 41. Transmission gear; 42. Passive gear ring; 43. Second screw; 44. Clamp; 45. Shaping table; 46. Rotating frame; 47. Pulley; 48. Third screw; 49. Connecting rod; 50. Support seat; 51. Three-axis acceleration sensor. DETAILED DESCRIPTION

[0021] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only used to explain the present invention and are not used to limit the scope of the present invention.

[0022] The present invention provides the following preferred embodiments like Figure 1-12 As shown, a high-quality copper casting welding device for connecting parts includes a base frame 1, a microcontroller 2, a vibration pressure frame 3 and a supplementary pressure frame 4, and the microcontroller 2 is fixedly mounted on the base frame 1; A transmission shaft 6 driven by a servo motor 5 is rotatably mounted on the base frame 1, and the end of the drive shaft 30 of the servo motor 5 is fixedly connected to the transmission shaft 6; A cradle 7 is rotatably mounted in the middle of the base frame 1, and two shaping arms 8 with adjustable spacing are mounted on the cradle 7, and two outer shaping wheels 9 are rotatably mounted on each shaping arm 8; A first screw rod 35 is rotatably mounted on the cradle 7. A first positive thread segment and a first negative thread segment are symmetrically arranged on the first screw rod 35. The first positive thread segment and the first negative thread segment are respectively connected to the two shaping arms 8 in a transmission manner. Both shaping arms 8 are integrated with an electric heater 36. The electric control end of the electric heater 36 is data-connected to the microcontroller 2. Both shaping arms 8 are slidably connected to the cradle 7. The electric heater 36 is integrated on the two shaping arms 8. Its core function is to achieve precise preheating and temperature maintenance of the welding area through the control of the microcontroller 2, providing a stable thermal environment for copper casting welding; Specifically, the copper pipe area to be welded is preheated before welding to reduce the hardness of the material to improve plastic fluidity and avoid cracks caused by excessive temperature difference during welding; During the welding process, the reciprocating shaking of the outer shaping wheel 9 is coordinated to continuously heat the heat-affected zone to offset the heat loss caused by vibration shaping. After welding, the gradient temperature is controlled to reduce the residual stress concentration. The temperature control logic adopts real-time monitoring, dynamic feedback, and multi-system linkage mechanism; The infrared temperature probe 21 continuously collects temperature data of the circumferential seam area to be welded. When the temperature is detected to be lower than the preset threshold, the microcontroller 2 increases the power of the electric heater 36 and reduces the vibration frequency of the vibration pressure frame 3 to reduce heat dissipation. During the welding phase, the molten pool temperature must be kept stable at 950-1050°C. If the measured temperature exceeds the upper limit, the microcontroller 2 immediately cuts off the output of part of the electric heater 36 and increases the vibration stroke of the vibration frame 3 to accelerate heat diffusion. During the cooling stage, the power of the electric heater 36 is gradually reduced, and the internal shaping wheel 22 is rotated at a low speed to achieve uniform cooling. Ultimately, the cooling rate is controlled at 5-8°C / s to avoid the precipitation of brittle phases caused by rapid cooling. The base frame 1 is provided with a reciprocating shaking system, a variable stroke driving system and a position-adjustable welding frame 10; When the transmission shaft 6 rotates, the reciprocating rocking system drives the cradle 7 to rock back and forth within ±35°; The reciprocating rocking system includes two rocking shafts 23 rotatably connected to the base frame 1 and an internal gear 24 fixedly mounted on the transmission shaft 6. The two rocking shafts 23 are respectively arranged on both sides of the transmission shaft 6. The two rocking shafts 23 are each mounted with an external gear 25 and a toothless gear 26. The two external gears 25 are both transmission-connected to the internal gear 24. A half-toothed ring gear 27 is mounted on the cradle 7. The toothless gear 26 is fixedly provided with a transmission tooth segment that meshes with the half-toothed ring gear 27. The center angle corresponding to the effective meshing area on the transmission tooth segment is 160°. The transmission tooth segments on the two toothless gears 26 are staggered by 180°. The reciprocating rocking system drives the internal gear 24 to rotate via the transmission shaft 6, thereby synchronously driving the external gear 25 and the toothless gear 26 on the rocking shafts 23 on both sides to rotate. Because the transmission tooth segments of the two toothless gears 26 are staggered by 180 degrees, and the effective meshing area center angle of a single transmission tooth segment is 160 degrees, when the toothless gear 26 rotates, its transmission tooth segments alternately mesh with the half-toothed ring gear 27 on the cradle 7, thereby driving the cradle 7 to achieve stable reciprocating rocking within a range of ±35 degrees. The ±35° swing range can dynamically adapt to the contour fluctuations caused by thermal deformation during the welding process of the copper casting when the outer shaping wheel 9 is welding and shaping, ensuring that the outer shaping wheel 9 always keeps in contact with the weld and heat-affected zone, avoiding sinking or cracking of the workpiece caused by local pressure concentration; At the same time, by periodically changing the pressure direction and position of the outer shaping wheel 9, the plastic fluidity of the metal material in the hot state is utilized to disperse the welding residual stress into multiple small areas and release it step by step, thereby promoting the grain breakage and rearrangement during the solidification process of the molten pool, reducing the tendency of columnar crystal growth, and improving the mechanical properties of the weld; In addition, during the swinging process, the dynamic contact between the outer shaping wheel 9 and the workpiece can assist in heat dissipation, avoiding oxidation or burn-through of the copper material caused by local overheating. Combined with the feedback of the infrared temperature probe 21, the microcontroller 2 can adjust the excitation parameters more accurately, ensuring a uniform temperature gradient in the welding area and reducing the risk of thermal cracks. This swing angle design also forms a synergy with the revolution and rotation of the inner shaping wheel 22. Through the compound motion of outward swing and inward rotation, geometric deviations such as weld excess height and misalignment are corrected in two directions, so that the flatness error of the workpiece after welding is reduced, meeting the requirements of high-precision assembly. At the same time, it is compatible with the welding of copper castings with different diameters or curvatures. There is no need to replace the shaping mold. The swing amplitude and frequency can be adjusted through program settings, improving the versatility of the equipment. The variable stroke drive system is provided with a guide frame 11, which is slidably connected to the vibration pressure frame 3 and a set of spring followers 12 are installed between the two. A micro-vibration frame 13 capable of horizontal vibration is slidably mounted on the vibration pressure frame 3. A return spring 14 is installed between the micro-vibration frame 13 and the vibration pressure frame 3. A vibration motor 15 is installed on the micro-vibration frame 13. A set of elastic pressure members 16 are installed between the micro-vibration frame 13 and the compensating pressure frame 4. The vibration frequency of the micro-vibration frame 13 is set to 200-500 Hz, which is higher than the critical frequency of bubble escape from the molten pool, and the amplitude is ≤ 0.5 mm to avoid porosity defects caused by molten pool disturbance; The variable stroke drive system includes a first linear transmission module 28 mounted on the base frame 1, a variable range frame 29 is transmission-mounted on the first linear transmission module 28, the variable range frame 29 is slidably connected to the base frame 1, a drive shaft 30 driven by a drive motor is rotatably mounted on the base frame 1, a hollow shaft 31 driven by the drive shaft 30 is rotatably mounted on the variable range frame 29, a semicircular trapezoidal table 32 is mounted on the hollow shaft 31, a transmission inclined plate 33 transmission-connected to the semicircular trapezoidal table 32 is mounted on the guide frame 11, a vibration pressure frame 3 is slidably connected to the base frame 1, and a group of return springs 34 limited by the base frame 1 are mounted on the vibration pressure frame 3; The circumferential coverage angle of the semicircular trapezoidal cone 32 is 180°. The axial cross-section of the semicircular trapezoidal cone 32 is an isosceles trapezoidal structure. The angle between the hypotenuse and the axis is 20°. The ratio of the large end radius to the small end radius of the semicircular trapezoidal cone 32 is 3:1. The surfaces of the transmission ramp 33 and the semicircular trapezoidal cone 32 are both provided with anti-slip transmission lines. The vibration frame 3 vibrates back and forth with variable stroke along the axis of the copper cast pipe 38 to be welded, which can subject the welding molten pool to periodic squeezing in the axial direction. During the vibration process, the liquid metal in the molten pool is more evenly distributed, which is conducive to filling the weld gap, reducing pores and incomplete weld defects, and making the internal structure of the weld denser. The micro-vibration frame 13 vibrates back and forth in a direction perpendicular to the copper cast pipe 38 to be welded, which can micro-shape the surface of the weld. It can make the weld surface height more uniform, reduce surface roughness, improve the appearance quality of the weld, and meet the requirements of high-precision assembly. The two vibration modes work together to change the stress distribution state during the welding process. The vibration along the axial direction promotes the dispersion of welding residual stress in the axial direction, while the vibration in the vertical direction disperses the stress in the radial direction, dispersing the concentrated residual stress into multiple small areas for step-by-step release, reducing welding deformation, improving the mechanical properties of the welded joint, and reducing the risk of thermal cracking. Vibration increases the heat exchange efficiency between the weldment and the surrounding air, assisting in heat dissipation. Especially when vibrating in the vertical direction, it expands the heat dissipation area and speed. Combined with the feedback from the infrared temperature probe 21, the microcontroller 2 can more accurately adjust the excitation parameters to ensure a uniform temperature gradient in the welding area, thus avoiding oxidation or burn-through of the copper material caused by local overheating. Different copper castings have different sizes, shapes and welding requirements. By adjusting the vibration parameters of the vibration pressure frame 3 and the micro-vibration frame 13, various complex welding conditions can be adapted. Whether it is a thin-walled or thick-walled copper casting pipe, a suitable vibration parameter combination can be found, improving the adaptability and versatility of the equipment for different welding tasks. The first visual probe 19 is used to obtain real-time image information of the welding area, identify the position and shape of the weld and the state of the molten pool during the welding process, and the microcontroller 2 determines the progress and quality of the welding based on this image information; When deviations in the weld seam or abnormalities in the molten pool are detected, such as spatter or signs of unfused welds, the microcontroller 2 will adjust the vibration frequency and stroke of the vibration and pressure frame 3 and the micro-vibration frame 13 accordingly; The adjustment commands of microcontroller 2 include speeding up the vibration frequency to promote the flow of the molten pool and correct the weld deviation; The second visual probe 20 mainly monitors the overall joint condition of the copper pipe 38 to be welded, including the amount of misalignment and the size of the gap. When a large amount of misalignment is detected, the microcontroller 2 can control the vibration frame 3 to increase the vibration stroke, using vibration to cause a slight displacement of the copper pipe to assist in aligning the weld; If the gap is too large or too small, the vibration frequency and amplitude are adjusted to optimize the filling effect of the welding pool. The infrared temperature probe 21 monitors the temperature of the welding area in real time. When the temperature is too high, the microcontroller 2 reduces the power of the vibration motor 15 to reduce the heat generated by the vibration, and at the same time increases the vibration stroke of the vibration pressure frame 3 to speed up the heat dissipation. When the temperature is too low, the power and vibration frequency of the vibration motor 15 are appropriately increased to enhance the heat input to the welding area; The microcontroller 2 adjusts the vibration stroke by controlling the first linear transmission module 28. Based on the analysis results of the collected data, it sends a control signal to the drive motor to change the driving direction and driving stroke of the first linear transmission module 28, thereby driving the range-changing frame 29 and the guide frame 11 to move, thereby achieving precise adjustment of the vibration stroke of the vibration pressure frame 3. The vibration frequency depends on the regulation of the drive motor. The microcontroller 2 adjusts the speed of the drive motor according to the data feedback. The change of the drive motor speed will change the rotation speed of the semicircular trapezoidal table 32, thereby causing the vibration frequency of the guide frame 11 and the vibration pressure frame 3 to change accordingly. For the control of the power of the vibration motor 15, the microcontroller 2 directly sends a power adjustment signal to the vibration motor 15. When the vibration effect needs to be enhanced, the voltage or current output to the vibration motor 15 is increased to increase the power of the vibration motor 15; Otherwise, the power output is reduced to achieve precise control of the vibration intensity of the micro-vibration frame 13; The pressure-compensating frame 4 and the welding frame 10 are both equipped with a rotating fixture driven by a transmission shaft 6; The welding frame 10 is slidably connected to the base frame 1. A second linear transmission module 37 is installed on the base frame 1. The second linear transmission module 37 is in transmission connection with the welding frame 10. The two rotating fixtures are each clamped with a copper cast pipe 38 to be welded. A ring seam to be welded is provided between the two copper cast pipes 38 to be welded. The reciprocating displacement direction of the vibration frame 3 is parallel to the axis of the copper pipe 38 to be welded, and the reciprocating displacement direction of the micro-vibration frame 13 is perpendicular to the axis of the copper pipe 38 to be welded; The copper cast pipe 38 to be welded is a hollow tubular structure with both ends open; The rotating fixture includes a rotating frame 39 and a hollow shaft 40. The rotating frame 39 and the hollow shaft 40 in the rotating fixture on the pressure-compensating frame 4 are both rotatably mounted on the pressure-compensating frame 4. The rotating frame 39 and the hollow shaft 40 in the rotating fixture on the welding frame 10 are both rotatably mounted on the welding frame 10. The hollow shaft 40 is linked to the transmission shaft 6. A transmission gear 41 is mounted on the hollow shaft 40. A passive gear ring 42 meshing with the transmission gear 41 is mounted on the rotating frame 39. A second screw rod 43 is rotatably mounted on the rotating frame 39. A second positive thread segment and a second negative thread segment are symmetrically provided on the second screw rod 43. The second positive thread segment and the second negative thread segment are both transmission-connected with a clamp 44 for clamping the copper cast pipe 38 to be welded. The clamp 44 is fixedly provided with an arc-shaped clamping portion that cooperates with the copper cast pipe 38 to be welded. A first through-slot with openings at both ends fixedly formed inside the hollow shaft 31 and slidably connected to the drive shaft 30 is fixedly formed inside the hollow shaft 40. A second through-slot with openings at both ends fixedly formed inside the hollow shaft 40 and slidably connected to the transmission shaft 6 is fixedly formed. The cross-sections of the first through-slot, the second through-slot, the transmission shaft 6, and the drive shaft 30 are all regular hexagons. The rotating fixture realizes stable power transmission while ensuring the vibration of the vibration frame 3 and the micro-vibration frame 13 through the sliding cooperation between the transmission shaft 6 and the hollow shaft 40. After the transmission shaft 6 drives the hollow shaft 40 to rotate, the transmission gear 41 and the passive ring gear 42 engage to drive the rotating frame 39 to rotate, so that the copper cast pipe 38 to be welded rotates synchronously, ensuring the continuity and uniformity of the circumferential seam welding. The design of the second positive thread section and the second negative thread section of the second screw rod 43 allows the distance between the clamps 44 to be quickly adjusted by the driving button. The arc-shaped clamping portion can fit closely to the outer surface of the copper cast pipe, improving the clamping stability. The transmission design of the regular hexagonal structure effectively avoids the slippage and power interruption problems that are prone to occur in traditional circular sleeves during vibration or sliding, ensuring that the rotation accuracy of the copper cast pipe is not affected during the vibration of the vibration pressure frame 3 and the micro-vibration frame 13. It solves the problem of welding deviation caused by power transmission failure or unstable clamping in a vibrating environment and ensures the consistency of the circumferential seam welding. A welding robot 17 is provided on the base frame 1. The execution end of the welding robot 17 is equipped with a welding gun 18 and a first visual probe 19 that is in communication with the microcontroller 2. A second visual probe 20 and an infrared temperature measuring probe 21 that are in communication with the microcontroller 2 are installed in the middle of the base frame 1. The microcontroller 2 dynamically adjusts the vibration stroke and vibration frequency of the vibration pressure frame 3 and the micro-vibration frame 13 in real time based on the data feedback from the first visual probe 19, the second visual probe 20 and the infrared temperature measuring probe 21. The data ends of the second visual probe 20 and the infrared temperature measuring probe 21 are both facing the annular seam to be welded; During welding, the first visual probe 19 can monitor the relative position of the welding gun 18 and the circumferential seam to be welded in real time, providing a precise positioning basis for the welding robot 17; The second visual probe 20 focuses on the circumferential seam area to be welded during welding to capture the morphological changes during the shaping and welding process; The infrared temperature probe 21 monitors the welding temperature field distribution in real time, and the microcontroller 2 integrates and analyzes the feedback data of the three, dynamically adjusting the vibration stroke of the vibration pressure frame 3 and the vibration frequency of the micro vibration frame 13, forming a closed-loop control of detection, analysis and adjustment; This system solves the problem of welding defects caused by reliance on manual experience and delayed parameter adjustment in traditional welding processes. Through intelligent dynamic control, it ensures that welding temperature, pressure and vibration parameters are always within the optimal range, significantly improving the quality stability and pass rate of copper casting welding. A shaping system is provided on the base frame 1 , and four inner shaping wheels 22 which can revolve and rotate synchronously are rotatably mounted on the shaping system corresponding to the positions of the outer shaping wheels 9 .

[0023] The inner shaping wheel 22 and the outer shaping wheel 9 are both made of stainless steel; The inner shaping wheel 22 and the outer shaping wheel 9 both correspond to the positions of the annular seams to be welded; The inner shaping wheel 22 is arranged on the inner side of the copper cast pipe 38 to be welded and realizes the synchronous inner shaping of the copper cast pipe 38 to be welded during welding. The outer shaping wheel 9 is arranged on the outer side of the copper cast pipe 38 to be welded and realizes the synchronous outer shaping of the copper cast pipe 38 to be welded during welding. The shaping system includes four shaping platforms 45, a rotating frame 46 rotatably connected to the base frame 1 and a pulley 47 fixedly mounted on the transmission shaft 6, the pulley 47 is connected to a synchronous toothed belt for transmission, the rotating frame 46 is connected to the synchronous toothed belt for transmission, a third screw rod 48 is rotatably mounted on the rotating frame 46, a third positive thread segment and a third negative thread segment are symmetrically arranged on the third screw rod 48, and an expansion support seat 50 is transmission-installed on the third positive thread segment and the third negative thread segment. The bottom surface of each shaping platform 45 is hinged to two connecting rods 49, and the other ends of the two connecting rods 49 are respectively hinged to the two expansion supports 50, and a strip hole that cooperates with the connecting rod 49 is opened on the rotating frame 46 and corresponds to the position of each shaping platform 45. The four inner shaping wheels 22 are rotatably mounted on the four shaping platforms 45 respectively.

[0024] The shaping system drives the pulley 47 and the synchronous toothed belt through the transmission shaft 6, driving the rotating frame 46 to rotate synchronously, so that the inner shaping wheel 22 revolves with the rotating frame 46. At the same time, the third positive thread segment and the third negative thread segment of the third screw rod 48 adjust the spacing between the expansion support seat 50, and push the shaping platform 45 to move radially through the connecting rod 49 to realize the rotation and position adjustment of the inner shaping wheel 22. The four inner shaping wheels 22 correspond to the outer shaping wheel 9 inside and outside. During the welding process of the copper casting pipe, the inner and outer sides are shaped synchronously. The revolution and rotation of the inner shaping wheel 22 cooperate with the reciprocating shaking of the outer shaping wheel 9 to form a three-dimensional shaping effect, which solves the problems of roundness deviation and local depression of the copper casting pipe after welding caused by traditional single-direction shaping, ensures the dimensional accuracy and structural strength of the copper casting after welding, and is especially suitable for the precision connection requirements of high-quality copper castings. The first screw rod 35, the second screw rod 43 and the third screw rod 48 are all equipped with drive buttons, and the micro-vibration frame 13 is equipped with a three-axis acceleration sensor 51. The data end of the three-axis acceleration sensor 51 is connected to the microcontroller 2. The servo motor 5 and the drive motor are both equipped with encoders connected to the microcontroller 2.

[0025] The driving buttons on the first screw rod 35, the second screw rod 43, and the third screw rod 48 can realize quick manual adjustment of the spacing between the shaping arms 8, the clamping range of the clamp 44, and the position of the inner shaping wheel 22, thereby improving the efficiency of equipment debugging. The three-axis acceleration sensor 51 collects the vibration parameters of the micro-vibration frame 13 in real time, and cooperates with the built-in encoder of the servo motor 5 and the drive motor to provide accurate motion state feedback for the microcontroller 2. This design solves the problem of poor process repeatability caused by the cumbersome parameter adjustment and lack of vibration state monitoring of traditional equipment. By combining manual adjustment with automatic monitoring, it not only ensures the flexibility of the equipment, but also ensures that the microcontroller 2 can perform precise control based on real operating data, further improving the controllability and stability of the welding process. The present invention realizes high-quality copper casting welding through the coordinated linkage of multiple systems. Its working principle is as follows: the servo motor 5 drives the transmission shaft 6 to rotate. On the one hand, the two toothless gears 26 of the reciprocating rocking system are driven by the internal gear 24 and the external gear 25 to alternately mesh with the half-toothed ring gear 27 of the cradle 7, so that the cradle 7 swings back and forth within ±35°, and cooperates with the outer shaping wheel 9 on the shaping arm 8 to dynamically shape the outer side of the weld. On the other hand, the shaping system rotating frame 46 is driven to rotate by the pulley 47, and the spacing of the expansion support seat 50 is adjusted in combination with the third screw 48, so that the inner shaping wheel 22 is synchronously rotated and the radial position is adjusted through the connecting rod 49, forming an internal and external coordinated shaping with the outer shaping wheel 9; In the variable stroke drive system, the drive motor drives the semicircular trapezoidal table 32 on the hollow shaft 31 to rotate, pushing the guide frame 11 to reciprocate through the transmission inclined plate 33, and transmitting the vibration to the vibration pressure frame 3 through the spring follower 12 to realize axial variable stroke vibration. At the same time, the vibration motor 15 on the micro-vibration frame 13 drives high-frequency micro-vibration perpendicular to the axis. The two vibrations act on the compensating pressure frame 4 through the elastic pressure member 16, forming a combined mechanical effect on the molten pool. The rotating fixture is linked to the transmission shaft 6 through the hollow shaft 40, driving the copper pipe 38 to be welded to rotate synchronously. The clamp 44 adjusted by the second screw 43 achieves stable clamping. The regular hexagonal transmission structure ensures uninterrupted power transmission under vibration conditions. During the welding process, the first visual probe 19 monitors the molten pool status in real time, the second visual probe 20 detects the accuracy of the circumferential seam, the infrared temperature measuring probe 21 monitors the temperature field distribution, and the three-axis acceleration sensor 51 feedbacks the vibration parameters. All data are collected by the microcontroller 2, which dynamically adjusts the stroke of the vibration frame 3, the frequency of the micro-vibration frame 13 and the parameters of the welding robot 17, forming a closed loop of detection, analysis and control.

[0026] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high-quality copper casting welding device for connecting parts, comprising a base frame, a microcontroller, a vibration pressure frame and a supplementary pressure frame, wherein a transmission shaft driven by a servo motor is rotatably mounted on the base frame, characterized in that: The middle part of the base frame is rotatably installed with a cradle, and two shaping arms with adjustable spacing are installed on the cradle. Two outer shaping wheels are rotatably installed on each shaping arm. A reciprocating shaking system, a variable stroke driving system and a position-adjustable welding frame are provided on the base frame. When the transmission shaft rotates, the reciprocating shaking system drives the cradle to shake back and forth within ±35°. A guide frame is installed on the variable stroke driving system. The guide frame is slidably connected to the vibration pressure frame and a group of spring followers are installed between the two. A micro-vibration frame that can vibrate horizontally is slidably installed on the vibration pressure frame. A reset spring is installed between the micro-vibration frame and the vibration pressure frame. A vibration motor is installed on the micro-vibration frame. The micro-vibration frame and the compensating pressure frame are connected. A group of elastic pressure parts are installed between the frames, and the pressure compensation frame and the welding frame are both equipped with rotating clamps driven by transmission shafts. A welding robot is provided on the base frame, and the execution end of the welding robot is equipped with a welding gun and a first visual probe connected to the microcontroller for communication. The middle part of the base frame is equipped with a second visual probe and an infrared temperature measuring probe connected to the microcontroller for communication. The microcontroller dynamically adjusts the vibration stroke and vibration frequency of the vibration pressure frame and the micro-vibration frame in real time based on the data feedback from the first visual probe, the second visual probe and the infrared temperature measuring probe. A shaping system is provided on the base frame, and four inner shaping wheels are installed on the shaping system and rotate corresponding to the position of the outer shaping wheel.

2. A high-quality copper casting welding device for connecting parts according to claim 1, characterized in that: The reciprocating rocking system includes two rocking shafts rotatably connected to the base frame and an internal gear fixedly mounted on the transmission shaft. The two rocking shafts are respectively arranged on both sides of the transmission shaft. The two rocking shafts are equipped with external gears and toothless gears. The two external gears are both connected to the internal gear in transmission. A half-toothed ring gear is installed on the rocking frame. The toothless gear is fixedly provided with a transmission tooth segment meshing with the half-toothed ring gear. The central angle corresponding to the effective meshing area on the transmission tooth segment is 160°, and the transmission tooth segments on the two toothless gears are staggered by 180°.

3. A high-quality copper casting welding device for connecting parts according to claim 1, characterized in that: The variable stroke drive system includes a first linear transmission module installed on the base frame, a variable range frame is installed on the first linear transmission module, the variable range frame is slidably connected to the base frame, a driving shaft driven by a driving motor is rotatably installed on the base frame, a hollow shaft driven by the driving shaft is rotatably installed on the range frame, a semicircular trapezoidal table is installed on the hollow shaft, a transmission inclined plate transmission-connected to the semicircular trapezoidal table is installed on the guide frame, the vibration pressure frame is slidably connected to the base frame and a group of return springs limited by the base frame are installed on the vibration pressure frame.

4. A high-quality copper casting welding device for connecting parts according to claim 3, characterized in that: The circumferential coverage angle of the semicircular trapezoidal cone is 180°, the axial cross-section of the semicircular trapezoidal cone is an isosceles trapezoidal structure, the angle between the hypotenuse on both sides and the axis is 20°, the ratio of the large end radius to the small end radius of the semicircular trapezoidal cone is 3:1, and the surfaces of the transmission inclined plate and the semicircular trapezoidal cone are provided with anti-slip transmission patterns.

5. A high-quality copper casting welding device for connecting parts according to claim 4, characterized in that: The microcontroller is fixedly mounted on the base frame, and a first screw rod is rotatably mounted on the cradle. A first positive thread segment and a first negative thread segment are symmetrically arranged on the first screw rod. The first positive thread segment and the first negative thread segment are respectively connected to the two shaping arms in a transmission manner. Electric heaters are integrated on the two shaping arms, and the two shaping arms are both slidably connected to the cradle.

6. A high-quality copper casting welding device for connecting parts according to claim 5, characterized in that: The welding frame is slidably connected to the base frame, and a second linear transmission module is installed on the base frame, and the second linear transmission module is transmission-connected to the welding frame. The two rotating fixtures are clamped with copper cast pipes to be welded, and a ring seam to be welded is provided between the two copper cast pipes to be welded. The data ends of the second visual probe and the infrared temperature measuring probe are both facing the ring seam to be welded, and the inner shaping wheel and the outer shaping wheel both correspond to the position of the ring seam to be welded. The reciprocating movement direction of the vibration frame is parallel to the axis of the copper cast pipe to be welded, and the reciprocating movement direction of the micro-vibration frame is perpendicular to the axis of the copper cast pipe to be welded.

7. A high-quality copper casting welding device for connecting parts according to claim 6, characterized in that: The rotating fixture includes a rotating frame and a hollow shaft. The rotating frame and the hollow shaft in the rotating fixture on the pressure-compensating frame are rotatably mounted on the pressure-compensating frame. The rotating frame and the hollow shaft in the rotating fixture on the welding frame are rotatably mounted on the welding frame. The hollow shaft is linked to the transmission shaft. A transmission gear is installed on the hollow shaft. A passive gear ring meshing with the transmission gear is installed on the rotating frame. A second screw rod is rotatably mounted on the rotating frame. A second positive thread segment and a second negative thread segment are symmetrically provided on the second screw rod. The second positive thread segment and the second negative thread segment are both transmission-connected with a clamp for clamping the copper cast pipe to be welded, and an arc-shaped clamping part that cooperates with the copper cast pipe to be welded is fixedly provided on the clamp.

8. A high-quality copper casting welding device for connecting parts according to claim 7, characterized in that: The hollow shaft is fixed with a first through groove with openings at both ends and slidingly connected to the drive shaft. The hollow shaft is fixed with a second through groove with openings at both ends and slidingly connected to the transmission shaft. The cross-sections of the first through groove, the second through groove, the transmission shaft and the drive shaft are all regular hexagons.

9. A high-quality copper casting welding device for connecting parts according to claim 7, characterized in that: The gear train is connected with the gear train by the gear train of the driven pulley, and the gear train is connected with the gear train of the driven pulley by the gear train, and the gear train is connected with the gear train of the driven pulley by the gear train.

10. A high-quality copper casting welding device for connecting parts according to claim 9, characterized in that: The first screw rod, the second screw rod and the third screw rod are all equipped with drive buttons, the micro-vibration frame is equipped with a three-axis acceleration sensor, the data end of the three-axis acceleration sensor is connected to the microcontroller data, and the servo motor and the drive motor are both equipped with encoders connected to the microcontroller data.

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