A high-quality copper casting welding device for connecting parts

Abstract

This invention relates to the field of welding equipment technology, specifically to a high-quality copper casting welding device for connecting parts. It includes a base frame, a microcontroller, a vibration pressure frame, and a pressure compensation frame. A drive shaft driven by a servo motor is rotatably mounted on the base frame. A rocker arm is rotatably mounted in the middle of the base frame, and two adjustable-spaced shaping arms are mounted on the rocker arm. Each shaping arm has two external shaping wheels rotatably mounted on it. The base frame is equipped with a reciprocating rocking system, a variable stroke drive system, and a position-adjustable welding frame. When the drive shaft rotates, the reciprocating rocking system drives the rocker arm to reciprocate within ±35°. A guide frame is mounted on the variable stroke drive system. The beneficial effects of this invention are: through internal and external coordinated dynamic shaping, intelligent closed-loop parameter adjustment, composite vibration pressure application, and multi-system automated linkage, this invention achieves real-time correction of thermal deformation and effective elimination of welding defects during the copper casting welding process.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, specifically to a high-quality copper casting welding device for connecting parts. Background Technology

[0002] Copper castings, due to their excellent electrical and thermal conductivity and mechanical properties, are widely used in high-end equipment fields such as aerospace, precision instruments, and rail transportation for component connections. The welding quality directly affects the operational reliability and service life of the entire machine. However, the welding process of copper and copper alloys presents numerous technical challenges, and existing welding equipment still faces the following prominent problems in achieving high-quality copper casting connections:

[0003] 1. Copper has a high thermal conductivity. During the welding process, the heat spreads rapidly, resulting in a large temperature gradient in the molten pool. This can easily lead to local overheating or uneven cooling, which in turn causes warping and shrinkage deformation 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 may also cause weld cracking due to secondary stress concentration.

[0004] 2. Existing welding equipment mostly uses fixed process parameters, which cannot respond to dynamic changes in the welding process in real time. When welding copper castings, the state of the molten pool, the joint gap, the amount of misalignment, etc. will change dynamically with the welding process. Fixed parameters are prone to defects such as incomplete penetration, porosity, and slag inclusion.

[0005] 3. Existing copper casting welding and shaping methods mostly adopt a single-sided static pressure method, which is difficult to cope with dynamic deformation during the welding process. External shaping easily ignores the inner weld seam protrusion, and internal support cannot correct the outer depression, resulting in problems such as local bulging and out-of-tolerance ovality of the workpiece after welding.

[0006] 4. Traditional welding processes rely heavily on the experience of operators. Weld positioning, parameter adjustment, and quality inspection are mostly done manually, resulting in problems such as slow response, insufficient accuracy, and large quality fluctuations.

[0007] Based on this, the present invention provides a high-quality copper casting welding apparatus for connecting parts to solve the problems mentioned in the background art. Summary of the Invention

[0008] This invention achieves real-time correction of thermal deformation and effective elimination of welding defects during the welding process of copper castings through internal and external collaborative dynamic shaping, intelligent closed-loop parameter adjustment, composite vibration pressure application, and multi-system automated linkage.

[0009] The technical solution of this invention to solve the above-mentioned technical problems is as follows: A high-quality copper casting welding device for connecting parts includes a base frame, a microcontroller, a vibratory pressing frame, and a pressure compensating frame. A transmission shaft driven by a servo motor is rotatably mounted on the base frame. A rocker arm is rotatably mounted in the middle of the base frame. Two adjustable-pitch shaping arms are mounted on the rocker arm, and two outer shaping wheels are rotatably mounted on each shaping arm. The base frame is provided with a reciprocating rocking system, a variable stroke drive system, and a position-adjustable welding frame. When the transmission shaft rotates, the reciprocating rocking system drives the rocker arm to reciprocate within ±35°. A guide frame is mounted on the variable stroke drive system. The guide frame is slidably connected to the vibratory pressing frame, and a set of spring followers are installed between them. A horizontally vibrating micro-vibrator is slidably mounted on the vibratory pressing frame. A return spring is installed between the frame and the vibration frame. A vibration motor is installed on the micro-vibration frame. A set of elastic pressure components is installed between the micro-vibration frame and the pressure-repairing frame. Rotary clamps driven by transmission shafts are installed on both the pressure-repairing frame and the welding frame. A welding robot is installed on the base frame. The execution end of the welding robot is equipped with a welding torch and a first vision probe that communicates with the microcontroller. A second vision probe and an infrared temperature probe that communicate with the microcontroller are installed in the middle of the base frame. The microcontroller dynamically adjusts the vibration stroke and vibration frequency of the vibration frame and the micro-vibration frame in real time based on the data feedback from the first vision probe, the second vision probe, and the infrared temperature probe. A shaping system is installed on the base frame. Four inner shaping wheels that can rotate synchronously and revolve are installed on the shaping system corresponding to the position of the outer shaping wheel.

[0010] The beneficial effects of this invention are:

[0011] 1. This invention designs a collaborative working mechanism of inner and outer dual shaping systems. The outer system drives the cradle to swing back and forth within ±35° via a reciprocating rocking system, causing 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 via a transmission shaft, causing the four inner shaping wheels to revolve synchronously. At the same time, the spacing of the expansion support seat is adjusted by the third lead screw, and the radial position of the inner shaping wheel is precisely adjusted by 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 is achieved during the welding process, replacing the traditional static shaping mode after welding. This effectively disperses residual welding stress, avoids weld cracking caused by secondary stress concentration, and controls the flatness error and ellipticity deviation to an extremely low range, significantly improving dimensional accuracy.

[0012] 2. This invention constructs a closed-loop control system for sensing, analysis, and regulation. The first vision probe monitors the molten pool morphology and weld deviation in real time, the second vision probe captures the misalignment and gap changes, and the infrared temperature probe tracks the temperature field distribution. All data is 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 are always adapted to the dynamic welding requirements. This mechanism effectively solves the defects such as incomplete penetration, porosity, and slag inclusion caused by fixed parameters, and improves the welding qualification rate.

[0013] 3. This invention designs a composite vibration pressure system. The vibration pressure frame performs variable-stroke reciprocating vibration along the axis of the copper casting tube to promote uniform filling of the molten pool. The micro-vibration frame performs high-frequency micro-vibration along the vertical axis to optimize the weld surface reinforcement and roughness. The two are connected by a spring follower and an elastic pressure component to form a flexible force transmission. With the help of the pressure supplement frame, dynamic pressure compensation is achieved. This composite vibration not only enhances heat exchange efficiency and assists in heat dissipation, but also corrects the misalignment through bidirectional mechanical action. With the synchronous rotation of the rotating fixture, uniform pressure and shaping are achieved throughout the circumferential weld, solving the problems of local bulging and dimensional deviation caused by traditional single-sided shaping, and meeting the requirements of high-precision assembly.

[0014] 4. This invention achieves full-process automated control through intelligent linkage of multiple systems. The servo motor drives the transmission shaft to synchronously link the reciprocating rocking system, the shaping system, and the rotating fixture, ensuring precise coordination of the outer shaping wheel's swing, the inner shaping wheel's revolution, and the copper casting tube's rotation. The microcontroller integrates visual inspection, temperature monitoring, and vibration sensing data to automatically adjust key process elements such as the welding robot's welding torch position, shaping arm spacing, and vibration parameters. From weld positioning and parameter adjustment to quality inspection, no manual intervention is required throughout the entire process, eliminating quality fluctuations caused by human experience and achieving high consistency and stability in the welding process, significantly improving production efficiency and product reliability.

[0015] Based on the above technical solution, the present invention can be further improved as follows.

[0016] 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 installed on the transmission shaft. The two rocking shafts are respectively arranged on both sides of the transmission shaft. An external gear and a toothed gear are installed on each of the two rocking shafts. Both of the external gears are connected to the internal gears for transmission. A half-toothed gear ring is installed on the rocking frame. A transmission tooth segment that meshes with the half-toothed gear ring is fixedly provided on the toothed gear. The center angle corresponding to the effective meshing area on the transmission tooth segment is 160°. The transmission tooth segments on the two toothed gears are staggered by 180°.

[0017] As a preferred technical solution of the present invention, the variable stroke drive system includes a first linear transmission module mounted on a base frame, a variable stroke frame mounted on the first linear transmission module, the variable stroke frame being slidably connected to the base frame, a drive shaft driven by a drive motor being rotatably mounted on the base frame, a hollow shaft driven by the drive shaft being rotatably mounted on the variable stroke frame, a semi-circular trapezoidal frustum mounted on the hollow shaft, a transmission inclined plate being mounted on the guide frame and slidably connected to the semi-circular trapezoidal frustum, and a set of return springs limited by the base frame being mounted on the vibration frame.

[0018] As a preferred technical solution of the present invention, the circumferential coverage angle of the semicircular trapezoidal frustum is 180°, the axial cross section of the semicircular trapezoidal frustum is an isosceles trapezoidal structure, the angle between the two hypotenuses and the axis is 20°, the ratio of the radius of the large end to the radius of the small end of the semicircular trapezoidal frustum is 3:1, and the surfaces of the transmission inclined plate and the semicircular trapezoidal frustum are provided with anti-slip transmission texture.

[0019] As a preferred technical solution of the present invention, the microcontroller is fixedly installed on the base frame, and a first lead screw is rotatably installed on the cradle. The first lead screw is symmetrically provided with a first positive thread section and a first negative thread section. The first positive thread section and the first negative thread section are respectively connected to two shaping arms for transmission. Each of the two shaping arms is integrated with an electric heater, and both shaping arms are slidably connected to the cradle.

[0020] As a preferred technical solution of the present invention, the welding frame is slidably connected to the base frame, a second linear transmission module is installed on the base frame, the second linear transmission module is connected to the welding frame in a transmission manner, two rotating clamps are each clamped with copper casting tubes to be welded, a welding circumferential seam is provided between the two copper casting tubes to be welded, the data ends of the second visual probe and the infrared temperature measuring probe are both facing the welding circumferential seam, the inner shaping wheel and the outer shaping wheel are both corresponding to the position of the welding circumferential seam, the reciprocating direction of the vibration frame is parallel to the axis of the copper casting tube to be welded, and the reciprocating direction of the micro-vibration frame is perpendicular to the axis of the copper casting tube to be welded.

[0021] 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-reducing frame are rotatably mounted on the pressure-reducing 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 with a transmission shaft. A transmission gear is installed on the hollow shaft. A driven gear ring that meshes with the transmission gear is installed on the rotating frame. A second lead screw is rotatably mounted on the rotating frame. A second positive thread section and a second negative thread section are symmetrically arranged on the second lead screw. A clamp for holding the copper casting pipe to be welded is drivenly connected to both the second positive thread section and the second negative thread section. An arc-shaped clamping part that cooperates with the copper casting pipe to be welded is fixedly provided on the clamp.

[0022] As a preferred technical solution of the present invention, the hollow shaft has a first through groove with openings at both ends and slidably connected to the drive shaft, and the hollow shaft has a second through groove with openings at both ends and slidably 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.

[0023] As a preferred technical solution of the present invention, the shaping system includes four shaping tables, a rotating frame rotatably connected to the base frame, and a pulley fixedly installed on the transmission shaft. A synchronous toothed belt is drivenly connected to the pulley, and the rotating frame is drivenly connected to the synchronous toothed belt. A third lead screw is rotatably installed on the rotating frame. A third positive thread section and a third negative thread section are symmetrically arranged on the third lead screw. An expansion seat is drivenly installed on both the third positive thread section and the third negative thread section. Two connecting rods are hinged to the bottom surface of each shaping table. The other ends of the two connecting rods are respectively hinged to the two expansion seats. A slot is opened on the rotating frame corresponding to the position of each shaping table to cooperate with the connecting rod. The four inner shaping wheels are rotatably installed on the four shaping tables respectively.

[0024] As a preferred embodiment of the present invention, drive buttons are installed on the first lead screw, the second lead screw and the third lead screw, a three-axis accelerometer is installed on the micro-vibration frame, the data terminal of the three-axis accelerometer is connected to the microcontroller, and the servo motor and the drive motor are both equipped with encoders that are connected to the microcontroller. Attached Figure Description

[0025] Figure 1 A schematic diagram of the overall structure of a high-quality copper casting welding device for connecting parts;

[0026] Figure 2 A schematic diagram of the structure of the vibration motor and the elastic pressure application component;

[0027] Figure 3 A schematic diagram of the second lead screw and clamp;

[0028] Figure 4 This is a schematic diagram of the cradle and the second vision probe.

[0029] Figure 5 for Figure 4 A magnified schematic diagram of the local structure at point A;

[0030] Figure 6 This is a structural diagram of the cradle and the outer shaping wheel;

[0031] Figure 7 This is a schematic diagram of the third lead screw and the drive shaft;

[0032] Figure 8 for Figure 7A magnified schematic diagram of the local structure at point B;

[0033] Figure 9 This is a schematic cross-sectional view of the rotating frame and the extended support base;

[0034] Figure 10 A schematic diagram of a semi-circular trapezoidal frustum and a return spring;

[0035] Figure 11 This is a structural schematic diagram of a welding robot;

[0036] Figure 12 This is an exploded structural diagram of the drive shaft and guide frame.

[0037] The attached diagram lists the components represented by each number as follows:

[0038] 1. Base frame; 2. Microcontroller; 3. Vibration frame; 4. Compensating frame; 5. Servo motor; 6. Drive shaft; 7. Cradle; 8. Shaping arm; 9. Outer shaping wheel; 10. Welding frame; 11. Guide frame; 12. Spring follower; 13. Micro-vibration frame; 14. Return spring; 15. Vibration motor; 16. Elastic pressure component; 17. Welding robot; 18. Welding torch; 19. First vision probe; 20. Second vision probe; 21. Infrared temperature probe; 22. Inner shaping wheel; 23. Cradle; 24. Internal gear; 25. External gear; 26. Gear with missing tooth; 27. Half 28. Gear ring; 29. ​​First linear transmission module; 30. Variable stroke frame; 31. Drive shaft; 32. Hollow shaft; 33. Semicircular trapezoidal frustum; 34. Transmission slant plate; 35. Return spring; 36. First lead screw; 37. Electric heater; 38. Second linear transmission module; 39. Copper casting pipe to be welded; 40. Rotating frame; 41. Hollow shaft; 42. Transmission gear; 43. Passive gear ring; 44. Second lead screw; 45. Clamp; 46. Shaping table; 47. Rotating frame; 48. Pulley; 49. Third lead screw; 50. Connecting rod; 51. Expansion support; 52. Triaxial accelerometer. Detailed Implementation

[0039] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0040] The present invention provides the following preferred embodiments.

[0041] 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 pressure compensation frame 4, wherein the microcontroller 2 is fixedly installed on the base frame 1.

[0042] A drive shaft 6 driven by a servo motor 5 is rotatably mounted on the base frame 1, and the drive shaft 30 end of the servo motor 5 is fixedly connected to the drive shaft 6.

[0043] A cradle 7 is rotatably mounted in the middle of the base frame 1. Two shaping arms 8 with adjustable spacing are mounted on the cradle 7. Two outer shaping wheels 9 are rotatably mounted on each shaping arm 8.

[0044] A first lead screw 35 is rotatably mounted on the rocker arm 7. A first positive thread section and a first negative thread section are symmetrically arranged on the first lead screw 35. The first positive thread section and the first negative thread section are respectively connected to two shaping arms 8. Each of the two shaping arms 8 integrates an electric heater 36. The electric control terminal of the electric heater 36 is connected to the microcontroller 2. Both shaping arms 8 are slidably connected to the rocker arm 7.

[0045] The electric heater 36 is integrated on the two forming arms 8. Its core function is to achieve precise preheating and temperature maintenance of the welding area through the microcontroller 2, so as to provide a stable thermal environment for the welding of copper castings.

[0046] Specifically, this means that the area to be welded in the copper casting pipe is preheated before welding to reduce the material hardness and improve plastic fluidity, thus avoiding cracks caused by excessive temperature difference during welding.

[0047] During the welding process, the reciprocating rocking of the outer shaping wheel 9 is used to continuously heat and compensate the heat-affected zone, offsetting the heat loss caused by vibration shaping. After welding, the residual stress concentration is reduced by gradient cooling control.

[0048] The temperature control logic employs a real-time monitoring, dynamic feedback, and multi-system linkage mechanism.

[0049] 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, microcontroller 2 increases the power of electric heater 36 and at the same time reduces the vibration frequency of vibrating frame 3 to reduce heat dissipation.

[0050] During the welding stage, the temperature of the molten pool must be kept stable at 950-1050℃. If the measured temperature exceeds the upper limit, the microcontroller 2 will immediately cut off part of the output of the electric heater 36 and increase the vibration stroke of the vibrating frame 3 to accelerate the heat dissipation.

[0051] During the cooling stage, the power of the electric heater 36 is gradually reduced, and the low-speed revolution of the inner shaping wheel 22 is used to achieve uniform cooling. The cooling rate is ultimately controlled at 5-8℃ / s to avoid the precipitation of brittle phases caused by rapid cooling.

[0052] The base frame 1 is equipped with a reciprocating rocking system, a variable stroke drive system, and a position-adjustable welding frame 10;

[0053] When the drive shaft 6 rotates, the reciprocating rocking system drives the rocker arm 7 to reciprocate within ±35°;

[0054] The reciprocating rocking system includes two rocker shafts 23 rotatably connected to the base frame 1 and an internal gear 24 fixedly installed on the transmission shaft 6. The two rocker shafts 23 are respectively located on both sides of the transmission shaft 6. An external gear 25 and a toothed gear 26 are installed on each of the two rocker shafts 23. The two external gears 25 are connected to the internal gear 24 for transmission. A half-tooth gear ring 27 is installed on the rocker frame 7. A transmission tooth segment that meshes with the half-tooth gear ring 27 is fixedly provided on the toothed gear 26. The center angle corresponding to the effective meshing area on the transmission tooth segment is 160°. The transmission tooth segments on the two toothed gears 26 are offset by 180°.

[0055] The reciprocating rocking system drives the internal gear 24 to rotate via the transmission shaft 6, which in turn drives the external gear 25 and the toothed gear 26 on the two rocking shafts 23 to rotate synchronously. Since the transmission tooth segments of the two toothed gears 26 are offset by 180° and the effective meshing area center angle of a single transmission tooth segment is 160°, when the toothed gear 26 rotates, its transmission tooth segments will alternately mesh with the half-tooth ring 27 on the rocker 7, thereby driving the rocker 7 to achieve stable reciprocating rocking within a range of ±35°.

[0056] With a swing range of ±35°, the outer forming wheel 9 can dynamically adapt to the contour fluctuations caused by thermal deformation during the welding process of copper castings, ensuring that the outer forming wheel 9 always keeps in contact with the weld and heat-affected zone, and avoids workpiece dents or cracks caused by local pressure concentration.

[0057] Meanwhile, 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 used to disperse the welding residual stress into multiple small areas and release it step by step, which promotes grain breakage and rearrangement during the solidification process of the molten pool, reduces the tendency of columnar crystal growth, and improves the mechanical properties of the weld.

[0058] In addition, during the oscillation process, the dynamic contact between the outer shaping wheel 9 and the workpiece can assist in heat dissipation, avoiding local overheating that could lead to copper oxidation or burn-through. 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 and reduce the risk of hot cracking.

[0059] The swing angle design also works in synergy with the revolution and rotation of the inner forming wheel 22. Through the combined motion of external swing and internal rotation, it corrects geometric deviations such as weld reinforcement and misalignment in both directions, thereby reducing the flatness error of the welded workpiece and 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 change the forming mold. The swing amplitude and frequency can be adjusted through program settings, which improves the versatility of the equipment.

[0060] A guide frame 11 is installed on the variable stroke drive system. The guide frame 11 is slidably connected to the vibratory frame 3 and a set of spring follower 12 is installed between the two.

[0061] A horizontally vibrating micro-vibrating frame 13 is slidably mounted on the vibrating frame 3. A return spring 14 is installed between the micro-vibrating frame 13 and the vibrating frame 3. A vibration motor 15 is mounted on the micro-vibrating frame 13. A set of elastic pressure-applying components 16 is installed between the micro-vibrating frame 13 and the pressure-replenishing frame 4.

[0062] The vibration frequency of the micro-vibrator 13 is set to 200-500Hz, which is higher than the critical frequency for bubble escape from the molten pool, and the amplitude is ≤0.5mm to avoid molten pool disturbance leading to porosity defects.

[0063] The variable stroke drive system includes a first linear transmission module 28 mounted on a base frame 1, a variable stroke frame 29 mounted on the first linear transmission module 28, the variable stroke frame 29 being slidably connected to the base frame 1, a drive shaft 30 driven by a drive motor being rotatably mounted on the base frame 1, a hollow shaft 31 driven by the drive shaft 30 being rotatably mounted on the variable stroke frame 29, a semi-circular trapezoidal frustum 32 being mounted on the hollow shaft 31, a transmission inclined plate 33 being mounted on the guide frame 11 and being slidably connected to the semi-circular trapezoidal frustum 32, and a set of return springs 34 being limited by the base frame 1 being mounted on the vibration frame 3.

[0064] The circumferential coverage angle of the semicircular trapezoidal frustum 32 is 180°. The axial section of the semicircular trapezoidal frustum 32 is an isosceles trapezoidal structure, and the angle between its two hypotenuses and the axis is 20°. The ratio of the radius of the large end to the radius of the small end of the semicircular trapezoidal frustum 32 is 3:1. The surfaces of the transmission inclined plate 33 and the semicircular trapezoidal frustum 32 are provided with anti-slip transmission texture.

[0065] The vibratory frame 3 reciprocates along the axis of the copper casting tube 38 to be welded, which can subject the weld pool to periodic compression in the axial direction. During the vibration, the liquid metal in the weld pool is more evenly distributed, which is conducive to filling the weld gap, reducing porosity and incomplete penetration defects, and making the internal structure of the weld more compact. The micro-vibration frame 13 reciprocates along the direction perpendicular to the copper casting tube 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.

[0066] The two vibration modes work together to change the stress distribution during the welding process. The vibration along the axial direction causes the welding residual stress to be dispersed axially, while the vibration in the vertical direction disperses the stress radially. This disperses the concentrated residual stress into multiple small areas and releases it step by step, reducing welding deformation, improving the mechanical properties of the welded joint, and reducing the risk of hot cracking.

[0067] Vibration increases the heat exchange efficiency between the weldment and the surrounding air, aiding 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 and avoid local overheating that could lead to copper oxidation or burn-through.

[0068] Different copper castings vary in size, shape, and welding requirements. By adjusting the vibration parameters of the vibratory 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 combination of vibration parameters can be found to improve the adaptability and versatility of the equipment for different welding tasks.

[0069] The first vision probe 19 is used to acquire 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 judges the progress and quality of the welding based on this image information.

[0070] When a deviation in the weld or an abnormality in the molten pool is detected, such as spatter or signs of incomplete fusion, the microcontroller 2 will adjust the vibration frequency and stroke of the vibratory frame 3 and the micro-vibrator 13 accordingly.

[0071] The microcontroller 2's adjustment commands include increasing the vibration frequency to promote molten pool flow and correct weld deviations;

[0072] The second vision probe 20 mainly monitors the overall docking of the copper casting tube 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 vibrating frame 3 to increase the vibration stroke and use the vibration to make the copper casting tube produce a small displacement to assist in aligning the weld.

[0073] If the gap is too large or too small, adjust the vibration frequency and amplitude to optimize the filling effect of the weld 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 vibration, while increasing the vibration stroke of the vibrating frame 3 to accelerate the heat dissipation.

[0074] When the temperature is too low, the power and vibration frequency of the vibration motor 15 should be increased appropriately to enhance the heat input to the welding area;

[0075] 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 variable stroke frame 29 and the guide frame 11 to move, so as to achieve precise adjustment of the vibration stroke of the vibrating frame 3.

[0076] The vibration frequency depends on the control of the drive motor. The microcontroller 2 adjusts the speed of the drive motor according to the data feedback. The change in the speed of the drive motor will change the rotation speed of the semi-circular trapezoidal frustum 32, thereby causing the vibration frequency of the guide frame 11 and the vibration pressure frame 3 to change accordingly.

[0077] 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 it is necessary to enhance the vibration effect, the voltage or current output to the vibration motor 15 is increased, thereby increasing the power of the vibration motor 15.

[0078] Conversely, the power output is reduced to achieve precise control of the vibration intensity of the micro-vibration frame 13;

[0079] Both the pressure-repairing frame 4 and the welding frame 10 are equipped with rotating clamps driven by the drive shaft 6;

[0080] The welding frame 10 is slidably connected to the base frame 1. The base frame 1 is equipped with a second linear transmission module 37, which is connected to the welding frame 10 in a transmission manner. Two rotating clamps each hold a copper casting pipe 38 to be welded, and a welding circumferential seam is provided between the two copper casting pipes 38 to be welded.

[0081] The reciprocating direction of the vibration frame 3 is parallel to the axis of the copper casting tube 38 to be welded, and the reciprocating direction of the micro-vibration frame 13 is perpendicular to the axis of the copper casting tube 38 to be welded.

[0082] The copper casting tube 38 to be welded is a hollow tubular structure with openings at both ends;

[0083] 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-reducing frame 4 are rotatably mounted on the pressure-reducing frame 4. The rotating frame 39 and the hollow shaft 40 in the rotating fixture on the welding frame 10 are rotatably mounted on the welding frame 10. The hollow shaft 40 is linked with the transmission shaft 6. A transmission gear 41 is mounted on the hollow shaft 40. A passive gear ring 42 that meshes with the transmission gear 41 is mounted on the rotating frame 39. A second lead screw 43 is rotatably mounted on the rotating frame 39. A second positive thread section and a second negative thread section are symmetrically arranged on the second lead screw 43. A clamp 44 for clamping the copper casting pipe 38 to be welded is connected to both the second positive thread section and the second negative thread section. An arc-shaped clamping part that cooperates with the copper casting pipe 38 to be welded is fixedly provided on the clamp 44.

[0084] The hollow shaft 31 has a first through groove with openings at both ends and slidably connected to the drive shaft 30. The hollow shaft 40 has a second through groove with openings at both ends and slidably connected to the transmission shaft 6. The cross-sections of the first through groove, the second through groove, the transmission shaft 6, and the drive shaft 30 are all regular hexagons.

[0085] The rotating fixture achieves stable power transmission while ensuring the vibration of the vibrating frame 3 and the micro-vibrating frame 13 through the sliding fit between the drive shaft 6 and the hollow shaft 40. After the drive shaft 6 drives the hollow shaft 40 to rotate, it drives the rotating frame 39 to rotate through the meshing of the drive gear 41 and the passive gear ring 42, so that the copper casting pipe 38 to be welded rotates synchronously, ensuring the continuity and uniformity of the circumferential weld.

[0086] The design of the second positive thread section and the second negative thread section of the second lead screw 43 allows for quick adjustment of the clamp 44 spacing via the drive button. The arc-shaped clamping part can closely fit the outer surface of the copper casting tube, improving clamping stability.

[0087] The transmission design of the regular hexagonal structure effectively avoids the slippage and power interruption problems that are prone to occur when the traditional circular bushing vibrates or slides. It ensures that the rotational accuracy of the copper casting tube is not affected during the vibration of the vibrating frame 3 and the micro-vibrating frame 13. It solves the welding deviation problem caused by power transmission failure or unstable clamping under vibration environment and ensures the consistency of circumferential weld.

[0088] A welding robot 17 is mounted on the base frame 1. The welding robot 17 is equipped with a welding torch 18 and a first vision probe 19 that is connected to the microcontroller 2. A second vision probe 20 and an infrared temperature probe 21 that are connected to the microcontroller 2 are mounted in the middle of the base frame 1. The microcontroller 2 dynamically adjusts the vibration stroke and vibration frequency of the vibrating frame 3 and the micro-vibrating frame 13 in real time based on the data feedback from the first vision probe 19, the second vision probe 20 and the infrared temperature probe 21.

[0089] The data terminals of the second visual probe 20 and the infrared temperature probe 21 are both facing the welded circumferential seam.

[0090] During welding, the first vision probe 19 can monitor the relative position of the welding torch 18 and the circumferential seam to be welded in real time, providing a precise positioning basis for the welding robot 17;

[0091] The second vision probe 20 focuses on the circumferential seam area to be welded during welding, capturing the morphological changes during the shaping and welding process;

[0092] Infrared temperature probe 21 monitors the welding temperature field distribution in real time. Microcontroller 2 integrates and analyzes the feedback data from the three sources, and dynamically adjusts the vibration stroke of vibrating frame 3 and the vibration frequency of micro-vibrating frame 13 to form a closed-loop control of detection, analysis and adjustment.

[0093] This system solves the welding defects caused by reliance on manual experience and lag in 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.

[0094] The base frame 1 is equipped with a shaping system, and four inner shaping wheels 22 that can rotate synchronously and revolve on the shaping system and are rotatably installed on the shaping system corresponding to the position of the outer shaping wheel 9.

[0095] Both the inner shaping wheel 22 and the outer shaping wheel 9 are made of stainless steel;

[0096] Both the inner shaping wheel 22 and the outer shaping wheel 9 correspond to the positions of the circumferential seam to be welded.

[0097] The inner shaping wheel 22 is set on the inner side of the copper casting tube 38 to be welded and realizes the synchronous inner shaping of the copper casting tube 38 to be welded during welding. The outer shaping wheel 9 is set on the outer side of the copper casting tube 38 to be welded and realizes the synchronous outer shaping of the copper casting tube 38 to be welded during welding.

[0098] The shaping system includes four shaping tables 45, a rotating frame 46 rotatably connected to the base frame 1, and a pulley 47 fixedly installed on the drive shaft 6. A synchronous toothed belt is driven to the pulley 47, and the rotating frame 46 is driven to the synchronous toothed belt. A third lead screw 48 is rotatably installed on the rotating frame 46. A third positive thread section and a third negative thread section are symmetrically arranged on the third lead screw 48. A support seat 50 is driven to be installed on both the third positive thread section and the third negative thread section. Two connecting rods 49 are hinged to the bottom surface of each shaping table 45. The other ends of the two connecting rods 49 are respectively hinged to the two support seats 50. A slot is opened on the rotating frame 46 corresponding to the position of each shaping table 45 to cooperate with the connecting rods 49. Four inner shaping wheels 22 are rotatably installed on the four shaping tables 45 respectively.

[0099] The shaping system drives the pulley 47 and synchronous toothed belt through the drive shaft 6, which drives 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 section and the third negative thread section of the third lead screw 48 adjust the distance of the expansion support 50, and push the shaping table 45 to move radially through the connecting rod 49, so as to realize the rotation and position adjustment of the inner shaping wheel 22. The four inner shaping wheels 22 correspond to the outer shaping wheels 9 inside and out. During the welding process of copper casting tube, the inner and outer sides are shaped simultaneously. The revolution and rotation of the inner shaping wheels 22, combined with the reciprocating rocking of the outer shaping wheels 9, form a three-dimensional shaping effect, which solves the problems of roundness deviation and local depression after welding of copper casting tube caused by traditional single-direction shaping, and ensures the dimensional accuracy and structural strength of the copper casting after welding. It is especially suitable for the precision connection requirements of high-quality copper castings.

[0100] Drive buttons are installed on the first lead screw 35, the second lead screw 43 and the third lead screw 48. A three-axis accelerometer 51 is installed on the micro vibration frame 13. The data terminal of the three-axis accelerometer 51 is connected to the microcontroller 2. The servo motor 5 and the drive motor are both built with encoders that are connected to the microcontroller 2.

[0101] The drive knobs on the first lead screw 35, the second lead screw 43, and the third lead screw 48 can quickly and manually adjust the spacing of the shaping arm 8, the clamping range of the clamp 44, and the position of the inner shaping wheel 22, improving the efficiency of equipment debugging. The three-axis accelerometer 51 collects the vibration parameters of the micro vibration frame 13 in real time. Together with the built-in encoder of the servo motor 5 and the drive motor, it provides the microcontroller 2 with accurate motion state feedback. This design solves the problems of cumbersome parameter adjustment and poor process repeatability caused by the lack of vibration state monitoring in 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 make accurate adjustments based on real operating data, further improving the controllability and stability of the welding process.

[0102] This invention achieves high-quality copper casting welding through multi-system coordinated linkage. Its working principle is as follows: The servo motor 5 drives the transmission shaft 6 to rotate. On the one hand, the internal gear 24 and the external gear 25 drive the two toothed gears 26 of the reciprocating rocking system to alternately mesh with the half-tooth ring 27 of the rocker 7, so that the rocker 7 reciprocates within ±35°. This works in conjunction 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 pulley 47 drives the shaping system frame 46 to rotate. Combined with the third lead screw 48 to adjust the spacing of the expansion support 50, the inner shaping wheel 22 revolves synchronously and the radial position is adjusted through the connecting rod 49, forming an internal and external coordinated shaping with the outer shaping wheel 9.

[0103] In the variable stroke drive system, the drive motor drives the semi-circular trapezoidal frustum 32 on the hollow shaft 31 to rotate, and pushes the guide frame 11 to reciprocate through the transmission inclined plate 33. The motion is transmitted to the vibration pressure frame 3 through the spring follower 12 to achieve 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 pressure compensation frame 4 through the elastic pressure application member 16, forming a compound mechanical effect on the molten pool.

[0104] The rotating clamp is linked to the transmission shaft 6 via the hollow shaft 40, which drives the copper casting tube 38 to be welded to rotate synchronously. The clamp 44, adjusted by the second lead screw 43, achieves stable clamping. The regular hexagonal transmission structure ensures uninterrupted power transmission under vibration conditions.

[0105] During the welding process, the first vision probe 19 monitors the state of the molten pool in real time, the second vision probe 20 detects the accuracy of the circumferential seam connection, the infrared temperature probe 21 monitors the temperature field distribution, and the triaxial acceleration sensor 51 feeds back vibration parameters. All data are aggregated to 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.

[0106] 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 within the protection scope of the present invention.

Claims

1. A high-quality copper casting welding device for connecting parts, comprising a base frame, a microcontroller, a vibration pressing frame, and a pressure compensating frame, wherein a transmission shaft driven by a servo motor is rotatably mounted on the base frame, characterized in that, A rocker arm is rotatably mounted in the middle of the base frame. Two adjustable-spaced shaping arms are mounted on the rocker arm, and each shaping arm has two external shaping wheels rotatably mounted on it. The base frame is equipped with a reciprocating rocking system, a variable stroke drive system, and a position-adjustable welding frame. When the drive shaft rotates, the reciprocating rocking system drives the rocker arm to reciprocate within ±35°. A guide frame is mounted on the variable stroke drive system, and the guide frame is slidably connected to the vibrating frame, with a set of spring followers installed between them. A horizontally vibrating micro-vibrating frame is slidably mounted on the vibrating frame, and a return spring is installed between the micro-vibrating frame and the vibrating frame. A vibration motor is mounted on the micro-vibrating frame, and the micro-vibrating frame is connected to the pressure compensation frame. A set of elastic pressure-applying components is installed between the frames. Rotary clamps driven by drive shafts are installed on both the pressure-repairing frame and the welding frame. A welding robot is mounted on the base frame. The welding robot's execution end is equipped with a welding torch and a first vision probe communicating with a microcontroller. A second vision probe and an infrared temperature probe, also communicating with the microcontroller, are installed in the middle of the base frame. The microcontroller dynamically adjusts the vibration stroke and frequency of the vibration pressure frame and the micro-vibration frame in real time based on data feedback from the first, second, and infrared temperature probes. A shaping system is installed on the base frame, with four inner shaping wheels rotatably mounted on the system corresponding to the positions of the outer shaping wheels. The variable stroke drive system includes a first linear transmission module mounted on a base frame, a variable stroke frame mounted on the first linear transmission module, the variable stroke frame being slidably connected to the base frame, a drive shaft driven by a drive motor rotatably mounted on the base frame, a hollow shaft driven by the drive shaft rotatably mounted on the variable stroke frame, a semi-circular trapezoidal frustum mounted on the hollow shaft, a transmission inclined plate tractively connected to the semi-circular trapezoidal frustum mounted on the guide frame, and a set of return springs limited by the base frame being mounted on the vibration frame, all slidably connected to the base frame. The welding frame is slidably connected to the base frame. A second linear transmission module is installed on the base frame and is connected to the welding frame. Two rotating clamps each hold a copper casting tube to be welded. A welding circumferential seam is provided between the two copper casting tubes. The data ends of the second visual probe and the infrared temperature probe are directly facing the welding circumferential seam. The inner shaping wheel and the outer shaping wheel correspond to the position of the welding circumferential seam. The reciprocating direction of the vibration frame is parallel to the axis of the copper casting tube to be welded, and the reciprocating direction of the micro-vibration frame is perpendicular to the axis of the copper casting tube to be welded.

2. The 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 located on both sides of the transmission shaft. Each rocking shaft is equipped with an external gear and a toothed gear. Both external gears are connected to the internal gears for transmission. A half-toothed gear ring is mounted on the rocking frame. The toothed gear is fixedly provided with a transmission tooth segment that meshes with the half-toothed gear ring. The center angle corresponding to the effective meshing area on the transmission tooth segment is 160°. The transmission tooth segments on the two toothed gears are staggered by 180°.

3. The high-quality copper casting welding device for connecting parts according to claim 1, characterized in that, The circumferential coverage angle of the semicircular trapezoidal frustum is 180°. The axial cross section of the semicircular trapezoidal frustum is an isosceles trapezoidal structure with the angle between its two hypotenuses and the axis being 20°. The ratio of the radius of the large end to the radius of the small end of the semicircular trapezoidal frustum is 3:

1. The surfaces of the transmission inclined plate and the semicircular trapezoidal frustum are both provided with anti-slip transmission textures.

4. A high-quality copper casting welding device for connecting parts according to claim 3, characterized in that, The microcontroller is fixedly mounted on the base frame, and a first lead screw is rotatably mounted on the cradle. The first lead screw has a first positive thread section and a first negative thread section symmetrically arranged on it. The first positive thread section and the first negative thread section are respectively connected to two shaping arms. Each of the two shaping arms has an integrated heater, and both shaping arms are slidably connected to the cradle.

5. A high-quality copper casting welding device for connecting parts according to claim 4, characterized in that, The rotating fixture includes a rotating frame and a hollow shaft. The rotating frame and hollow shaft of the rotating fixture on the pressure-reducing frame are rotatably mounted on the pressure-reducing frame. The rotating frame and hollow shaft of the rotating fixture on the welding frame are rotatably mounted on the welding frame. The hollow shaft is linked with a transmission shaft. A transmission gear is installed on the hollow shaft. A driven gear ring that meshes with the transmission gear is installed on the rotating frame. A second lead screw is rotatably mounted on the rotating frame. A second positive thread section and a second negative thread section are symmetrically arranged on the second lead screw. Clamps for holding the copper casting pipe to be welded are drivenly connected to both the second positive thread section and the second negative thread section. An arc-shaped clamping part that cooperates with the copper casting pipe to be welded is fixedly provided on the clamp.

6. A high-quality copper casting welding device for connecting parts according to claim 5, characterized in that, The hollow shaft has a first through groove with openings at both ends and slidably connected to the drive shaft. The hollow shaft also has a second through groove with openings at both ends and slidably 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.

7. A high-quality copper casting welding device for connecting parts according to claim 6, characterized in that, The shaping system includes four shaping tables, a rotating frame rotatably connected to a base frame, and a pulley fixedly mounted on a drive shaft. A synchronous toothed belt is drivenly connected to the pulley, and the rotating frame is drivenly connected to the synchronous toothed belt. A third lead screw is rotatably mounted on the rotating frame. The third lead screw has a third positive thread section and a third negative thread section symmetrically arranged. Both the third positive thread section and the third negative thread section are drivenly mounted with expansion seats. Two connecting rods are hinged to the bottom surface of each shaping table. The other ends of the two connecting rods are respectively hinged to the two expansion seats. The rotating frame has slots corresponding to the positions of each shaping table, which cooperate with the connecting rods. The four inner shaping wheels are rotatably mounted on the four shaping tables respectively.

8. A high-quality copper casting welding device for connecting parts according to claim 7, characterized in that, A drive button is installed on the first lead screw, the second lead screw and the third lead screw. A three-axis accelerometer is installed on the micro vibration frame. The data terminal of the three-axis accelerometer is connected to the microcontroller. The servo motor and the drive motor are both equipped with encoders that are connected to the microcontroller.

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