Automatic welding system and method for gantry assembly of stacking machine

Abstract

The invention belongs to the technical field of stacking machine portal production, and particularly relates to an automatic welding system and method for a stacking machine portal assembly. A sliding rail clamping assembly is used for clamping two sliding rail components; the beam and plate components are clamped and mounted at the two ends of the sliding rail component through the beam and plate feeding assembly; two sliding sleeve components are installed on the outer side of each sliding rail component in a sleeving mode through the sliding sleeve feeding assembly; a carrier plate component is jointly clamped and mounted on the four sliding sleeve components through a carrier plate feeding assembly; a plurality of anti-falling inner supporting components are installed in the sliding rail component through an inner supporting filling assembly; a first fastening piece and a second fastening piece are additionally installed through a screw turning machine; the beam plate component and the sliding rail component are welded and fixed through a first welding assembly; the carrier plate component and the sliding sleeve component are welded and fixed through the second welding assembly, and automatic welding and assembling of the stacking machine portal frame assembly are achieved; the anti-falling inner supporting component can provide multi-stage buffering and is suitable for loading explosive objects, fragile objects or high-value objects.

Description

Technical Field

[0001] This invention belongs to the field of forklift gantry manufacturing technology, specifically relating to an automated welding system and method for forklift gantry components. Background Technology

[0002] The mast assembly is one of the core structures of a forklift, primarily responsible for supporting, guiding, and lifting goods. It consists of a fixed mast and a movable mast, driven by hydraulic cylinders to achieve lifting and lowering movements, ensuring goods are smoothly and accurately delivered to the designated height. The mast design directly affects the forklift's load-bearing capacity, stability, and operational efficiency. Its structure typically uses high-strength steel to withstand heavy loads and the impact of frequent operations. Rollers and guide rail systems installed on the mast reduce friction, making the lifting process smoother. Furthermore, the mast is equipped with chain or wire rope transmission devices that work in conjunction with the hydraulic system to achieve vertical transport of goods. Some masts also integrate lateral movement functionality, facilitating fork position adjustment and improving operational flexibility. The height and lifting speed of the mast assembly can be customized according to working conditions to meet the logistics handling needs of different scenarios. Its stability and durability are key factors in ensuring the long-term safe operation of the forklift.

[0003] The existing automated welding system for forklift gantry assemblies has several shortcomings. First, it cannot install anti-fall internal support components in the forklift gantry assembly. When the winder malfunctions, it cannot provide multi-level buffer support for the movable gantry, causing the movable gantry and its loaded items to fall suddenly. This makes it unsuitable for loading explosive, fragile, or high-value items. Second, it cannot pre-assemble the relevant components before welding, relying solely on welding for fixation, which results in unsatisfactory fixation reliability.

[0004] In view of this, the inventors hope to optimize and improve the existing automated welding system for forklift gantry components. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned problems existing in the prior art and to provide an automated welding system and method for forklift gantry components.

[0006] To achieve the above-mentioned technical objectives and effects, the present invention is implemented through the following technical solution: This invention provides an automated welding system for a forklift gantry assembly, including a controller and connected to it a slide rail clamping assembly, a beam loading assembly, a sliding sleeve loading assembly, a carrier plate loading assembly, an internal support filling assembly, a screw tightening machine, a first welding assembly, and a second welding assembly. The slide rail components, beam plate components, sliding sleeve components, carrier plate components, and anti-fall internal support components together constitute the forklift gantry assembly. The slide rail clamping assembly is used to clamp two slide rail components arranged side-by-side. The beam plate loading assembly is used to snap the beam plate components onto both ends of the slide rail components. The sliding sleeve loading assembly is used to... Two sliding sleeve components are sleeved and installed on the outside of each slide rail component; the carrier plate loading assembly is used to jointly snap the carrier plate component onto the four sliding sleeve components; the inner support filling assembly is used to install a number of spaced-apart anti-fall inner support components in the slide rail component; the screw tightening machine is used to install a first fastener between the beam plate component and the slide rail component and a second fastener between the anti-fall inner support component and the slide rail component; the first welding assembly is used to weld and fix the beam plate component and the slide rail component thereon; the second welding assembly is used to weld and fix the carrier plate component to each sliding sleeve component.

[0007] Furthermore, in the aforementioned automated welding system, the slide rail component is composed of a channel plate portion and a slide rail portion. The outer side of the web of the channel plate portion is provided with a slide rail portion with a T-shaped cross section. The two side plates of the channel plate portion are provided with first mounting holes near their ends to facilitate the installation of first fasteners. The inner side plates of the channel plate portion are provided with a plurality of second mounting holes at intervals to facilitate the installation of second fasteners. The outer side plates of the channel plate portion are provided with windows distributed opposite to the corresponding second mounting holes. The slide rail clamping assembly includes a first base plate, a first vertical push rod, a guide tube, a first mounting plate, and mechanical grippers. The first base plate is supported by the first vertical push rod and the guide tube, and two sets of mechanical grippers for clamping the slide rail part of the slide rail component are installed on the upper side of the first mounting plate.

[0008] Furthermore, in the aforementioned automated welding system, the beam-plate component consists of a beam-plate and symmetrically arranged snap-fit ​​blocks on its inner side. The shape of the snap-fit ​​blocks matches the shape of the inner cavity of the grooved plate in the slide rail component. The snap-fit ​​blocks are provided with a first positioning hole that mates with a first fastener. The beam plate loading assembly includes a first linear guide rail pair, a second vertical push rod, a first suction cup mounting slot, and a first suction cup. The second vertical push rod is installed on the lower side of the slider of the first linear guide rail pair, and the movable end of the second vertical push rod is mounted with a first suction cup for adsorbing the beam plate in the beam plate component via the first suction cup mounting slot.

[0009] Furthermore, in the aforementioned automated welding system, the sliding sleeve component is composed of a sliding sleeve body and a snap-fit ​​plate. The sliding sleeve body has an internal cavity that mates with the slide rail component. A snap-fit ​​plate with a T-shaped cross-section is fixed to the outside of the sliding sleeve body. The sliding sleeve body has an exposed opening near the window. The sliding sleeve feeding assembly includes a second linear guide pair, a third vertical push rod, a second suction cup mounting slot, and a second suction cup. The third vertical push rod is installed on the lower side of the slider of the second linear guide pair. The movable end of the third vertical push rod is mounted with a second suction cup for adsorbing the sliding sleeve body in the sliding sleeve component via the second suction cup mounting slot.

[0010] Furthermore, in the above-mentioned automated welding system, the carrier plate component consists of a carrier plate body, and two sets of L-shaped plates are symmetrically arranged on the inner side of the carrier plate body. The two L-shaped plates in the same set together form a T-shaped snap-fit ​​groove that cooperates with the snap-fit ​​plate. The carrier plate body is provided with several mounting holes to facilitate the installation of the movable gantry. The carrier plate loading assembly includes a third linear guide pair, a fourth vertical push rod, a third suction cup mounting bracket, and a third suction cup. The fourth vertical push rod is mounted on the upper side of the slider of the third linear guide pair, and the movable end of the fourth vertical push rod is mounted with a third suction cup for adsorbing the carrier plate body in the carrier plate assembly via the third suction cup mounting bracket.

[0011] Furthermore, in the aforementioned automated welding system, the anti-fall inner support component includes a mounting box, the mounting box having an internal movable cavity, a sliding plate being slidably restricted within the movable cavity, an anti-fall block being fixed to the outside of the sliding plate and penetrating one side plate of the mounting box, the anti-fall block having symmetrically provided guide bevels, a compression spring being installed on the inside of the sliding plate, and a second positioning hole being provided on the other side plate of the mounting box for engaging with a second fastener; The inner support filling assembly includes a fourth linear guide pair, a fifth vertical push rod, a fourth suction cup mounting bracket, a fourth suction cup, a toggle motor, and a toggle plate. The fifth vertical push rod is mounted on the lower side of the slider of the fourth linear guide pair. The movable end of the fifth vertical push rod is mounted with a third suction cup for adsorbing the mounting box in the fall arrestor inner support component and a toggle motor via the fourth suction cup mounting bracket. The output end of the toggle motor is mounted with a toggle plate that can push the fall arrestor block to slide inward.

[0012] Furthermore, in the aforementioned automated welding system, the screw-tightening machine is installed at the free end of the multi-axis robot as an end effector.

[0013] Furthermore, in the aforementioned automated welding system, the first welding assembly includes a fifth linear guide pair, a sixth vertical push rod, an electric gripper, an arc-shaped gripper, an arc-shaped guide pair slide rail, an arc-shaped guide pair slider, a radial push rod, and a first welding head. The sixth vertical push rod is mounted on the lower side of the slider of the fifth linear guide pair. An electric gripper is mounted on the movable end of the sixth vertical push rod. The electric gripper has two arc-shaped grippers that can rotate relative to each other. An arc-shaped guide pair slide rail that can be joined together is mounted on the inner side of the two arc-shaped grippers. An arc-shaped guide pair slider that forms an arc-shaped guide pair with the arc-shaped guide pair is mounted on the arc-shaped guide pair slide rail. The first welding head is mounted on the outer side of the arc-shaped guide pair slider via the radial push rod.

[0014] Furthermore, in the aforementioned automated welding system, the second welding assembly includes a sixth linear guide pair, a seventh vertical push rod, a slotted mounting plate, a lead screw motor, a lead screw, a movable block, an adjustment mechanism, and a second welding head. The seventh vertical push rod is mounted on the upper side of the slider of the sixth linear guide pair. The movable end of the seventh vertical push rod is mounted with a lead screw motor via the slotted mounting plate. The output end of the lead screw motor is connected to a lead screw. The lead screw has two lead screw segments with opposite rotation directions. A movable block is sleeved on the outer side of each lead screw segment. One end of the movable block abuts against the inner wall of the web of the slotted mounting plate. The movable block is mounted with a second welding head via the adjustment mechanism.

[0015] The present invention also provides an automated welding method for a forklift gantry assembly, based on the above-mentioned automated welding system, comprising the following steps: S1. The two slide rail components are clamped and fixed side by side by the slide rail clamping assembly to ensure their positional accuracy and stability during the welding process; S2. Two sliding sleeve components are fitted on the outside of each sliding rail component using the sliding sleeve feeding assembly. Then, the carrier plate feeding assembly is used to snap the carrier plate components onto the four sliding sleeve components. The second welding assembly is used to weld and fix the carrier plate components to each sliding sleeve component. During welding, symmetrical welding is required to balance thermal stress and avoid twisting of the gantry assembly. S3. Use the beam plate loading assembly to snap the beam plate components to both ends of the slide rail components, and use a screw tightening machine to install the first fastener for pre-fixation; use the first welding assembly to weld the connection between the beam plate components and the slide rail components, adopt a multi-layer multi-pass welding process to reduce thermal deformation, and control the welding current and speed to ensure the weld strength. S4. Use the internal support filling component to install anti-fall internal support components at intervals inside the slide rail component, and fix them by adding a second fastener with a screw tightening machine.

[0016] The beneficial effects of this invention are: 1. This invention provides an automated welding system for a forklift gantry assembly, which mainly consists of a controller, a slide rail clamping assembly, a beam plate loading assembly, a sliding sleeve loading assembly, a carrier plate loading assembly, an inner support filling assembly, a screw-tightening machine, a first welding assembly, and a second welding assembly. The slide rail clamping assembly clamps two slide rail components arranged side-by-side; the beam plate loading assembly clamps the beam plate components at both ends of the slide rail components; the sliding sleeve loading assembly sleeves two sliding sleeve components on the outside of each slide rail component; the carrier plate loading assembly clamps the carrier plate components onto four sliding sleeve components; the inner support filling assembly installs several spaced-apart anti-fall inner support components within the slide rail components; the screw-tightening machine installs a first fastener between the beam plate components and the slide rail components, and a second fastener between the anti-fall inner support components and the slide rail components; the first welding assembly welds and fixes the beam plate components to the corresponding slide rail components; and the second welding assembly welds and fixes the carrier plate components to each sliding sleeve component. This method achieves automated welding and assembly of the forklift gantry assembly with high assembly efficiency.

[0017] 2. The forklift gantry assembly of this invention, assembled by welding, mainly consists of slide rail components, beam plate components, sliding sleeve components, carrier plate components, and anti-fall inner support components. Four sliding sleeve components are used to jointly install the carrier plate components. The back side of the carrier plate components serves as the connection surface for the winder, and the front side serves as the mounting surface for the movable gantry. The beam plate components fix the positions of the two slide rail components. By installing several anti-fall inner support components at intervals between the slide rail components, when the movable gantry and its loaded items slowly rise and fall, the anti-fall blocks of the anti-fall inner support components can adaptively extend and retract without affecting the rising and falling. When the winder malfunctions, the anti-fall inner support components can provide multi-level buffering for the rapidly falling movable gantry and its loaded items, making it suitable for loading explosive, fragile, or high-value items.

[0018] Of course, any product implementing this invention does not necessarily need to achieve all of the above advantages at the same time. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a connection block diagram of the main electrical components in this invention; Figure 2 This is a schematic diagram of the structure of the forklift gantry assembly at one angle in this invention; Figure 3 for Figure 2A magnified view of a portion of point A in the middle; Figure 4 This is a schematic diagram of the forklift gantry assembly from another angle in this invention; Figure 5 This is an exploded view of the forklift gantry assembly in this invention; Figure 6 This is a schematic diagram of the slide rail component in this invention; Figure 7 This is a structural schematic diagram of the beam-slab component in this invention; Figure 8 This is a schematic diagram of the sliding sleeve component in this invention; Figure 9 This is a schematic diagram of the structure of the carrier plate component in this invention; Figure 10 This is a schematic diagram of the internal structure of the anti-fall inner support component in this invention; Figure 11 This is a schematic diagram of the external structure of the anti-fall inner support component in this invention; Figure 12 This is a schematic diagram of the slide rail clamping assembly in this invention; Figure 13 This is a schematic diagram of the beam-plate loading assembly in this invention; Figure 14 This is a schematic diagram of the sliding sleeve feeding assembly in this invention; Figure 15 This is a schematic diagram of the structure of the carrier plate loading assembly in this invention; Figure 16 This is a schematic diagram of the internal support filling component in this invention; Figure 17 This is a schematic diagram of the structure of the first welding assembly in this invention; Figure 18 This is a schematic diagram of the structure of the second welding assembly in this invention; In the attached diagram, the components represented by each number are as follows: 1-Controller; 2-Slide rail clamping assembly, 201-First base plate, 202-First vertical push rod, 203-Guide tube, 204-First mounting plate, 205-Mechanical gripper; 3-Beam plate loading assembly, 301-First linear guide pair, 302-Second vertical push rod, 303-First suction cup mounting slot, 304-First suction cup; 4-Sliding sleeve feeding assembly, 401-Second linear guide pair, 402-Third vertical push rod, 403-Second suction cup mounting slot, 404-Second suction cup; 5-Carrier plate loading assembly, 501-Third linear guide pair, 502-Fourth vertical push rod, 503-Third suction cup mounting bracket, 504-Third suction cup; 6-Inner support filling assembly, 601-Fourth linear guide pair, 602-Fifth vertical push rod, 603-Fourth suction cup mounting bracket, 604-Fourth suction cup, 605-Toggle motor, 606-Toggle plate; 7- Screw tightening machine; 8-First welding assembly, 801-Fifth linear guide pair, 802-Sixth vertical push rod, 803-Electric gripper, 804-Arc-shaped gripper, 805-Arc-shaped guide pair slide rail, 806-Arc-shaped guide pair slider, 807-Radial push rod, 808-First welding head; 9-Second welding assembly, 901-Sixth linear guide pair, 902-Seventh vertical push rod, 903-Slotted mounting plate, 904-Screw motor, 905-Screw, 906-Modible block, 907-Tilting mechanism, 908-Second welding head; 10-Slide rail component, 101-Slot plate part, 102-Slide rail part, 103-First mounting hole, 104-Second mounting hole, 105-Window; 11-Beam-slab component, 111-Beam-slab, 112-Snap-fit ​​block, 113-First positioning hole; 12-First fastener; 13-Sliding sleeve component, 131-Sliding sleeve body, 132-Snap-fit ​​plate, 133-Exposed opening; 14-Carrier plate component, 141-Carrier plate body, 142-L-shaped plate, 143-T-shaped snap-fit ​​groove, 144-Mounting hole; 15-Anti-fall inner support component, 151-Mounting box, 152-Moving cavity, 153-Slide plate, 154-Anti-fall stop block, 155-Guide bevel, 156-Compression spring, 157-Second positioning hole; 16 - Second fastener. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] like Figures 1-5As shown, this embodiment provides an automated welding system for a forklift gantry assembly, including a controller 1 and connected to it a slide rail clamping assembly 2, a beam plate loading assembly 3, a sliding sleeve loading assembly 4, a carrier plate loading assembly 5, an inner support filling assembly 6, a screw tightening machine 7, a first welding assembly 8, and a second welding assembly 9; the slide rail component 10, the beam plate component 11, the sliding sleeve component 13, the carrier plate component 14, and the anti-fall inner support component 15 together constitute the forklift gantry assembly; the slide rail clamping assembly 2 is used to clamp two slide rail components 10 arranged side by side; the beam plate loading assembly 3 is used to snap the beam plate component 11 onto both ends of the slide rail component 10; the sliding sleeve loading assembly 4 is used to... Two sliding sleeve components 13 are sleeved and installed on the outside of each slide rail component 10; the carrier plate loading assembly 5 is used to jointly snap and install the carrier plate component 14 on the four sliding sleeve components 13; the inner support filling assembly 6 is used to install a number of spaced anti-fall inner support components 15 in the slide rail component 10; the screw tightening machine 7 is used to install the first fastener 12 between the beam plate component 11 and the slide rail component 10 and to install the second fastener 16 between the anti-fall inner support component 15 and the slide rail component 10; the first welding assembly 8 is used to weld and fix the beam plate component 11 and the slide rail component 10 thereon; the second welding assembly 9 is used to weld and fix the carrier plate component 14 to each sliding sleeve component 13.

[0023] like Figure 6 As shown, the slide rail component 10 is composed of a channel plate portion 101 and a slide rail portion 102. The slide rail portion 102 with a T-shaped cross section is provided on the outer side of the web of the channel plate portion 101. The two side plates of the channel plate portion 101 are provided with first mounting holes 103 near the ends to facilitate the installation of the first fastener 12. The inner side plate of the channel plate portion 101 is provided with a plurality of second mounting holes 104 at intervals to facilitate the installation of the second fastener 16. The outer side plate of the channel plate portion 101 is provided with windows 105 distributed opposite to the corresponding second mounting holes 104.

[0024] like Figure 12 As shown, the slide rail clamping assembly 2 includes a first base plate 201, a first vertical push rod 202, a guide tube 203, a first mounting plate 204, and mechanical grippers 205. The first base plate 201 supports the first mounting plate 204 via the first vertical push rod 202 and the guide tube 203. Two sets of mechanical grippers 205 for clamping the slide rail portion 102 in the slide rail component 10 are mounted on the upper side of the first mounting plate 204. The working principle of the slide rail clamping assembly 2 is as follows: the height of the mechanical grippers 205 is adjusted by the first vertical push rod 202, the guide tube 203 ensures vertical movement accuracy, and the mechanical grippers 205 clamp the slide rail portion 102 to achieve side-by-side positioning of the two slide rail components 10.

[0025] like Figure 7As shown, the beam plate component 11 consists of a beam plate 111 and symmetrically arranged snap-fit ​​blocks 112 on its inner side. The shape of the snap-fit ​​blocks 112 matches the shape of the inner cavity of the groove plate portion 101 in the slide rail component 10. The snap-fit ​​blocks 112 are provided with a first positioning hole 113 that matches the first fastener 12.

[0026] like Figure 13 As shown, the beam plate loading assembly 3 includes a first linear guide rail pair 301, a second vertical push rod 302, a first suction cup mounting slot 303, and a first suction cup 304. The second vertical push rod 302 is mounted on the lower side of the slider of the first linear guide rail pair 301. The movable end of the second vertical push rod 302 is mounted with a first suction cup 304 via the first suction cup mounting slot 303 for adsorbing the beam plate 111 in the beam plate component 11. The working principle of the beam plate loading assembly 3 is as follows: the first linear guide rail pair 301 achieves horizontal positioning, the second vertical push rod 302 controls lifting, and the first suction cup 304 adsorbs the beam plate 111 and accurately engages it in the inner cavity of the groove plate part 101.

[0027] like Figure 8 As shown, the sliding sleeve component 13 is composed of a sliding sleeve body 131 and a snap-fit ​​plate 132. The sliding sleeve body 131 has a sliding cavity inside that cooperates with the slide rail component 10. The snap-fit ​​plate 132 with a T-shaped cross section is fixed on the outside of the sliding sleeve body 131. The sliding sleeve body 131 has an exposed opening 133 located near the window 105.

[0028] like Figure 14 As shown, the sliding sleeve feeding assembly 4 includes a second linear guide pair 401, a third vertical push rod 402, a second suction cup mounting slot 403, and a second suction cup 404. The third vertical push rod 402 is mounted on the lower side of the slider of the second linear guide pair 401. The movable end of the third vertical push rod 402 is mounted with a second suction cup 404 via the second suction cup mounting slot 403 for adsorbing the sliding sleeve body 131 in the sliding sleeve component 13. The working principle of the sliding sleeve feeding assembly 4 is as follows: the second linear guide pair 401 controls the horizontal movement, the third vertical push rod 402 adjusts the height, and the second suction cup 404 adsorbs the sliding sleeve body 131 and then slides into the sliding rail portion 102.

[0029] like Figure 9 As shown, the carrier plate component 14 consists of a carrier plate body 141. Two sets of L-shaped plates 142 are symmetrically arranged on the inner side of the carrier plate body 141. The two L-shaped plates 142 in the same set together form a T-shaped snap-fit ​​groove 143 that cooperates with the snap-fit ​​plate 132. The carrier plate body 141 has several mounting holes 144 for easy installation of the movable gantry.

[0030] like Figure 15As shown, the carrier plate loading assembly 5 includes a third linear guide pair 501, a fourth vertical push rod 502, a third suction cup mounting bracket 503, and a third suction cup 504. The fourth vertical push rod 502 is mounted on the upper side of the slider of the third linear guide pair 501. The movable end of the fourth vertical push rod 502 is connected to the third suction cup 504 via the third suction cup mounting bracket 503 for adsorbing the carrier plate body 141 in the carrier plate component 14. The working principle of the carrier plate loading assembly 5 is as follows: the third linear guide pair 501 controls the horizontal movement, the fourth vertical push rod 502 adjusts the height, and after the third suction cup 504 adsorbs the carrier plate body 141, it docks with the clamping plate 132 through the T-shaped clamping groove 143.

[0031] like Figures 10-11 As shown, the fall arrestor inner support component 15 includes a mounting box 151. The mounting box 151 has an internal movable cavity 152. A sliding plate 153 is slidably restricted in the movable cavity 152. A fall arrestor block 154 is fixed on the outside of the sliding plate 153, penetrating one side plate of the mounting box 151. The fall arrestor block 154 has symmetrically provided guide bevels 155. A compression spring 156 is installed on the inside of the sliding plate 153. The other side plate of the mounting box 151 has a second positioning hole 157 that cooperates with the second fastener 16.

[0032] like Figure 16 As shown, the inner support filling component 6 includes a fourth linear guide pair 601, a fifth vertical push rod 602, a fourth suction cup mounting bracket 603, a fourth suction cup 604, a toggle motor 605, and a toggle plate 606. The fifth vertical push rod 602 is mounted on the lower side of the slider of the fourth linear guide pair 601. The movable end of the fifth vertical push rod 602 is mounted with a third suction cup 504 for adsorbing the mounting box 151 in the anti-fall inner support component 15 via the fourth suction cup mounting bracket 603, as well as a toggle motor 605. The output end of the toggle motor 605 is mounted with a toggle plate 606 that can push the anti-fall block 154 to slide inward. The working principle of the inner support filling component 6 is as follows: the fourth linear guide pair 601 controls the horizontal movement, the fifth vertical push rod 602 adjusts the height, and the fourth suction cup 604 adsorbs the mounting box 151 and inserts it into the inner cavity of the slotted plate part 101. During the insertion process, the toggle motor 605 drives the toggle plate 606 to flip, and the anti-fall block 154 retracts inward a certain distance through the guide inclined edge 155 on the upper side of the anti-fall block 154. Then, the edge of the slotted plate part 101 slides and abuts against the guide inclined edge 155 on the lower side of the anti-fall block 154, so that the anti-fall block 154 continues to retract inward until the mounting box 151 is completely inserted into the inner cavity of the slotted plate part 101. At this time, the anti-fall block 154 extends out of the window 105 under the restoring action of the compression spring 156.

[0033] In this embodiment, the screw tightening machine 7 is installed at the free end of the multi-axis robot as an end effector. The multi-axis robot, carrying the end effector, completes the automatic tightening of the first fastener 12 and the second fastener 16.

[0034] like Figure 17 As shown, the first welding assembly 8 includes a fifth linear guide rail pair 801, a sixth vertical push rod 802, an electric gripper 803, an arc-shaped gripper 804, an arc-shaped guide rail pair slide rail 805, an arc-shaped guide rail pair slider 806, a radial push rod 807, and a first welding head 808. The sixth vertical push rod 802 is installed on the lower side of the slider of the fifth linear guide rail pair 801. An electric gripper 803 is installed on the movable end of the sixth vertical push rod 802. The electric gripper 803 has two arc-shaped grippers 804 that can rotate relative to each other. An arc-shaped guide rail pair slide rail 805 that can be joined together is installed on the inner side of the two arc-shaped grippers 804. An arc-shaped guide rail pair slider 806 that forms an arc-shaped guide rail pair with the arc-shaped guide rail pair is installed on the arc-shaped guide rail pair slide rail 805. The first welding head 808 is installed on the outer side of the arc-shaped guide rail pair slider 806 via the radial push rod 807. The working principle of the first welding component 8 is as follows: the arc-shaped claw 804 clamps the outer area of ​​the welding part, the arc-shaped guide rail auxiliary slider 806 drives the first welding head 808 to move along the circumference, and the radial push rod 807 drives the first welding head 808 to move radially, so as to realize the circumferential welding between the beam plate component 11 and the slide rail component 10.

[0035] like Figure 18 As shown, the second welding assembly 9 includes a sixth linear guide pair 901, a seventh vertical push rod 902, a slotted mounting plate 903, a lead screw motor 904, a lead screw 905, a movable carrier block 906, a tilting mechanism 907, and a second welding head 908. The seventh vertical push rod 902 is mounted on the upper side of the slider of the sixth linear guide pair 901. The movable end of the seventh vertical push rod 902 is mounted with the lead screw motor 904 via the slotted mounting plate 903. The output end of the lead screw motor 904 is connected to the lead screw 905. The lead screw 905 has two lead screw segments with opposite directions of rotation. A movable carrier block 906 is sleeved on the outer side of each lead screw segment. One end of the movable carrier block 906 abuts against the inner wall of the web of the slotted mounting plate 903. The second welding head 908 is mounted on the movable carrier block 906 via the tilting mechanism 907. The working principle of the second welding assembly 9: the lead screw motor 904 drives the bidirectional lead screw 905 to make the two second welding heads 908 move synchronously and symmetrically, and the tilting mechanism 907 adjusts the angle of the welding gun to achieve symmetrical welding of the carrier plate component 14 and the sliding sleeve component 13.

[0036] This embodiment also provides an automated welding method for forklift gantry components, including the following steps: S1. The two slide rail components 10 are clamped and fixed side by side by the slide rail clamping assembly 2 to ensure their positional accuracy and stability during the welding process; S2. Two sliding sleeve components 13 are fitted on the outside of each sliding rail component 10 by the sliding sleeve feeding assembly 4. Then, the carrier plate component 14 is snapped onto the four sliding sleeve components 13 by the carrier plate feeding assembly 5. The carrier plate component 14 is welded and fixed to each sliding sleeve component 13 by the second welding assembly 9. During welding, symmetrical welding is required to balance thermal stress and avoid twisting of the gantry component. S3. The beam plate component 11 is snapped to both ends of the slide rail component 10 using the beam plate loading assembly 3, and the first fastener 12 is pre-fixed by the screw tightening machine 7; the connection between the beam plate component 11 and the slide rail component 10 is welded using the first welding assembly 8, and a multi-layer multi-pass welding process is adopted to reduce thermal deformation, and the welding current and speed are controlled to ensure the weld strength. S4. Anti-fall inner support components 15 are installed at intervals inside the slide rail component 10 using the inner support filling component 6, and fixed by adding a second fastener 16 using a screw tightening machine 7.

[0037] The forklift gantry assembly welded and assembled in this embodiment mainly consists of slide rail components, beam plate components, sliding sleeve components, carrier plate components, and anti-fall inner support components. Four sliding sleeve components are used to jointly install the carrier plate component. The back side of the carrier plate component serves as the connection surface for the winder, and the front side serves as the mounting surface for the movable gantry. The beam plate components fix the positions of the two slide rail components. By installing several anti-fall inner support components at intervals between the slide rail components, when the movable gantry and its loaded items slowly rise and fall, the anti-fall blocks of the anti-fall inner support components can adaptively extend and retract without affecting the rising and falling. When the winder malfunctions, the anti-fall inner support components can provide multi-level buffering for the rapidly falling movable gantry and its loaded items, making it suitable for loading explosive, fragile, or high-value items.

[0038] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to specific implementations. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An automated welding system for a forklift gantry assembly, characterized in that, The system includes a controller and connected components such as a slide rail clamping assembly, a beam loading assembly, a sliding sleeve loading assembly, a carrier plate loading assembly, an inner support filling assembly, a screw tightening machine, a first welding assembly, and a second welding assembly. The slide rail components, beam plate components, sliding sleeve components, carrier plate components, and anti-fall inner support components together constitute a forklift gantry assembly. The slide rail clamping assembly clamps two slide rail components arranged side-by-side. The beam plate loading assembly snaps the beam plate components onto both ends of the slide rail components. The sliding sleeve loading assembly sleeves two sliding sleeve components on the outside of each slide rail component. The carrier plate loading assembly snaps the carrier plate components onto four sliding sleeve components. The inner support filling assembly installs several spaced-apart anti-fall inner support components within the slide rail components. The screw-tightening machine is used to install a first fastener between the beam plate component and the slide rail component, and to install a second fastener between the anti-fall inner support component and the slide rail component; the first welding assembly is used to weld and fix the beam plate component and the slide rail component thereon; the second welding assembly is used to weld and fix the carrier plate component to each sliding sleeve component.

2. The automated welding system according to claim 1, characterized in that; The slide rail component is composed of a grooved plate and a slide rail. The outer side of the web of the grooved plate is provided with a slide rail with a T-shaped cross section. The two side plates of the grooved plate are provided with first mounting holes near the ends to facilitate the installation of first fasteners. The inner side plates of the grooved plate are provided with several second mounting holes to facilitate the installation of second fasteners. The outer side plates of the grooved plate are provided with windows that are distributed opposite to the corresponding second mounting holes. The slide rail clamping assembly includes a first base plate, a first vertical push rod, a guide tube, a first mounting plate, and mechanical grippers. The first base plate is supported by the first vertical push rod and the guide tube, and two sets of mechanical grippers for clamping the slide rail part of the slide rail component are installed on the upper side of the first mounting plate.

3. The automated welding system according to claim 2, characterized in that, The beam-plate component consists of a beam-plate and symmetrically arranged snap-fit ​​blocks on its inner side. The shape of the snap-fit ​​blocks matches the shape of the inner cavity of the groove plate in the slide rail component. A first positioning hole is provided in the snap-fit ​​block to cooperate with the first fastener. The beam plate loading assembly includes a first linear guide rail pair, a second vertical push rod, a first suction cup mounting slot, and a first suction cup. The second vertical push rod is installed on the lower side of the slider of the first linear guide rail pair, and the movable end of the second vertical push rod is mounted with a first suction cup for adsorbing the beam plate in the beam plate component via the first suction cup mounting slot.

4. The automated welding system according to claim 1, characterized in that, The sliding sleeve component consists of a sliding sleeve body and a snap-fit ​​plate. The sliding sleeve body has a sliding cavity inside that mates with the slide rail component. A snap-fit ​​plate with a T-shaped cross-section is fixed to the outside of the sliding sleeve body. The sliding sleeve body has an exposed opening near the window. The sliding sleeve feeding assembly includes a second linear guide pair, a third vertical push rod, a second suction cup mounting slot, and a second suction cup. The third vertical push rod is installed on the lower side of the slider of the second linear guide pair. The movable end of the third vertical push rod is mounted with a second suction cup for adsorbing the sliding sleeve body in the sliding sleeve component via the second suction cup mounting slot.

5. The automated welding system according to claim 1, characterized in that, The carrier plate component consists of a carrier plate body, on the inner side of which two sets of L-shaped plates are symmetrically arranged. The two L-shaped plates in the same set together form a T-shaped snap-fit ​​groove that mates with the snap-fit ​​plate. The carrier plate body has several mounting holes for easy installation of the movable gantry. The carrier plate loading assembly includes a third linear guide pair, a fourth vertical push rod, a third suction cup mounting bracket, and a third suction cup. The fourth vertical push rod is mounted on the upper side of the slider of the third linear guide pair, and the movable end of the fourth vertical push rod is mounted with a third suction cup for adsorbing the carrier plate body in the carrier plate assembly via the third suction cup mounting bracket.

6. The automated welding system according to claim 1, characterized in that, The fall arrestor inner support component includes a mounting box, the mounting box has an internal movable cavity, a sliding plate is slidably restricted in the movable cavity, a fall arrestor block is fixed on the outside of the sliding plate and penetrates one side plate of the mounting box, the fall arrestor block has symmetrically opened guide bevels, a compression spring is installed on the inside of the sliding plate, and a second positioning hole is opened on the other side plate of the mounting box to cooperate with the second fastener. The inner support filling assembly includes a fourth linear guide pair, a fifth vertical push rod, a fourth suction cup mounting bracket, a fourth suction cup, a toggle motor, and a toggle plate. The fifth vertical push rod is mounted on the lower side of the slider of the fourth linear guide pair. The movable end of the fifth vertical push rod is mounted with a third suction cup for adsorbing the mounting box in the fall arrestor inner support component and a toggle motor via the fourth suction cup mounting bracket. The output end of the toggle motor is mounted with a toggle plate that can push the fall arrestor block to slide inward.

7. The automated welding system according to claim 1, characterized in that, The screw-tightening machine is installed at the free end of the multi-axis robot as an end effector.

8. The automated welding system according to claim 1, characterized in that, The first welding assembly includes a fifth linear guide rail pair, a sixth vertical push rod, an electric gripper, an arc-shaped gripper, an arc-shaped guide rail pair slide rail, an arc-shaped guide rail pair slider, a radial push rod, and a first welding head. The sixth vertical push rod is installed on the lower side of the slider of the fifth linear guide rail pair. An electric gripper is installed on the movable end of the sixth vertical push rod. The electric gripper has two arc-shaped grippers that can rotate relative to each other. An arc-shaped guide rail pair slide rail that can be joined together is installed on the inner side of the two arc-shaped grippers. An arc-shaped guide rail pair slider that forms an arc-shaped guide rail pair with the arc-shaped guide rail pair is installed on the arc-shaped guide rail pair slide rail. The first welding head is installed on the outer side of the arc-shaped guide rail pair slider via the radial push rod.

9. The automated welding system according to claim 1, characterized in that, The second welding assembly includes a sixth linear guide pair, a seventh vertical push rod, a slotted mounting plate, a lead screw motor, a lead screw, a movable block, a tilting mechanism, and a second welding head. The seventh vertical push rod is mounted on the upper side of the slider of the sixth linear guide pair. The movable end of the seventh vertical push rod is mounted with a lead screw motor via the slotted mounting plate. The output end of the lead screw motor is connected to a lead screw. The lead screw has two lead screw segments with opposite directions of rotation. A movable block is sleeved on the outer side of each lead screw segment. One end of the movable block abuts against the inner wall of the web of the slotted mounting plate. The movable block is mounted with a second welding head via the tilting mechanism.

10. An automated welding method for a forklift gantry assembly, implemented based on the automated welding system described in claim 9, characterized in that, Includes the following steps: S1. The two slide rail components are clamped and fixed side by side by the slide rail clamping assembly to ensure their positional accuracy and stability during the welding process; S2. Two sliding sleeve components are fitted on the outside of each sliding rail component using the sliding sleeve feeding assembly. Then, the carrier plate feeding assembly is used to snap the carrier plate components onto the four sliding sleeve components. The second welding assembly is used to weld and fix the carrier plate components to each sliding sleeve component. During welding, symmetrical welding is required to balance thermal stress and avoid twisting of the gantry assembly. S3. Use the beam plate loading assembly to snap the beam plate components to both ends of the slide rail components, and use a screw tightening machine to install the first fastener for pre-fixation; use the first welding assembly to weld the connection between the beam plate components and the slide rail components, adopt a multi-layer multi-pass welding process to reduce thermal deformation, and control the welding current and speed to ensure the weld strength. S4. Use the internal support filling component to install anti-fall internal support components at intervals inside the slide rail component, and fix them by adding a second fastener with a screw tightening machine.

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