Automatic puppet welding system

Abstract

The invention provides an automatic puppet welding system and relates to the technical field of automobile manufacturing, the automatic puppet welding system comprises a power box, a clamping tool, a robot, puppet welding tongs and a control unit, the power box is provided with a power interface, the clamping tool is provided with a positioning part and a clamping part, the robot rotates in and rotates out a workpiece, and the puppet welding tongs are provided with a driver, a fixed arm and a movable arm. The driver drives the movable arm to be far away from and close to the fixed arm, the fixed arm is provided with a first conductive part connected with the power interface, the first conductive part is provided with a supporting face, the movable arm is provided with a second conductive part connected with the power interface, and the second conductive part is provided with a conductive contact head. A workpiece at the welding position is clamped between the supporting face and the conductive contact head, and the control unit is used for controlling the power box, the robot and the driver to conduct corresponding actions. Automatic welding can be achieved, the occupied space of the structure is reduced, and the risk that welding spot pits are formed in the surface of an outer part is reduced.

Description

Technical Field

[0001] This invention relates to the field of automobile manufacturing technology, and in particular to an automated puppet welding system. Background Technology

[0002] Puppet welding is a special type of resistance spot welding process, with the same principle as resistance welding. It utilizes an external welding machine's welding clamp to provide welding current and control parameters, transmitting the current to the puppet welding clamp via conductors such as copper busbars and cables. The puppet welding clamp presses against the workpiece to be welded, forming a circuit. Welding is achieved by utilizing the resistance heat generated when the current flows through the joint contact surface and adjacent areas. The core value of this process lies in solving problems such as insufficient welding space at the weld location, high operational difficulty, and potential safety hazards.

[0003] In the automotive manufacturing industry, particularly at the body assembly station, puppet welding is widely used for welding exterior body structural components to improve efficiency and quality. Existing puppet welding machines in welding workshops typically include manual welding clamps, puppet welding clamps, and a copper busbar cable system connecting them. Both the upper and lower electrodes of the puppet welding clamp are equipped with standard electrode caps, allowing direct contact with the workpiece during spot welding to form weld points.

[0004] However, existing puppet welding mechanisms are complex in design and occupy significant space to accommodate the operation of manual welding guns, making them difficult to use in extremely confined areas such as the lower part of the workpiece. Furthermore, because both upper and lower electrodes use electrode cap structures, the pressure is concentrated during welding, easily forming weld depressions on the workpiece surface (especially on exterior parts), severely affecting aesthetics and corrosion resistance, and failing to meet high-quality appearance requirements. In addition, existing technology heavily relies on manual operation of the puppet welding gun, making it impossible to integrate into automated production lines. This not only reduces production efficiency and increases labor costs but also introduces safety risks, failing to meet the demands of modern welding workshops for automated production. Summary of the Invention

[0005] This invention aims to at least solve one of the technical problems existing in the prior art. To this end, this invention proposes an automated puppet welding system that can achieve automated welding, reduce the space occupied by the structure, and reduce the risk of weld point depressions on the surface of the exterior parts.

[0006] An automated puppet welding system according to an embodiment of the present invention includes a power supply box, a clamping fixture, a robot, a puppet welding clamp, and a control unit. The power supply box is provided with a power interface. The clamping fixture is provided with a positioning part and a clamping part. The positioning part is used to position the workpiece, and the clamping part is used to clamp the workpiece at a preset position after positioning. The robot is used to transfer the workpiece onto the clamping fixture and to transfer the welded workpiece off the clamping fixture. The puppet welding clamp has a driver, a fixed arm, and a movable arm. The driver drives the movable arm to move away from and towards the fixed arm. The fixed arm is provided with a cable assembly. A first conductive part connected to the power interface has a support surface that matches the shape of the welding position on the workpiece. The movable arm has a second conductive part connected to the power interface via the cable assembly. The second conductive part has an arc-shaped conductive contact. When the fixed arm and the movable arm are close to a preset position, the welding position on the workpiece is clamped between the support surface and the conductive contact. The control unit is used to control the power box to output electrical energy from the power interface according to preset welding parameters, and to control the robot and the driver to perform corresponding actions.

[0007] The automated puppet welding system according to embodiments of the present invention has at least the following beneficial effects: the system integrates a robot (responsible for loading and unloading), a clamping fixture (responsible for positioning and clamping), a puppet welding gun (responsible for performing welding), and a control unit (responsible for global coordination and control). The control unit controls the power supply box to output electrical energy according to preset welding parameters and synchronously controls the robot's movements and the opening and closing movements of the puppet welding gun driver. This automated closed-loop design eliminates the dependence on manual operation in traditional puppet welding, and can be seamlessly integrated into automated production lines, improving the production efficiency and consistency of welding operations, reducing labor costs, and eliminating the safety hazards of manual operation. Furthermore, the control coordination between the power supply box and the control unit eliminates the need for manual operation of the welding gun in traditional puppet welding. The large and complex mechanical structure accommodates the operating space of the manual welding clamp; meanwhile, the fixed arm of the puppet welding clamp is directly mounted on the clamping fixture, and its support surface matches the shape of the workpiece welding position, ensuring stable contact positioning; in addition, the first conductive part of the fixed arm has a support surface that matches the shape of the welding position on the workpiece, and the second conductive part of the movable arm has an arc-shaped conductive contact head. When the workpiece is clamped between the support surface and the conductive contact head, the support surface provides large-area stable support and disperses the welding pressure; the arc-shaped contact head reduces the local pressure on the workpiece surface. Through the combined effect of these two, the risk of weld point depressions on the workpiece surface (especially appearance parts) during the welding process is reduced, greatly improving the surface quality, aesthetics and corrosion resistance of the weld joint.

[0008] According to some embodiments of the present invention, the fixed arm includes a support and a first conductive block. The support is fixed on the clamping fixture. The support is provided with a first cantilever. The first conductive block is insulatedly disposed at the extended end of the first cantilever. The supporting surface is formed on the surface of the first conductive block. The first conductive block is connected to the power interface through the cable assembly.

[0009] According to some embodiments of the present invention, a first insulating pad is sandwiched between the first cantilever and the first conductive block.

[0010] According to some embodiments of the present invention, the first conductive block is detachably mounted on the first cantilever by means of insulating fasteners.

[0011] According to some embodiments of the present invention, the movable arm includes a rotating base and a second conductive block. The rotating base is rotatably connected to the support, and the driver is drively connected to the rotating base. The support is provided with a second cantilever. The second conductive block is insulatedly disposed at the extended end of the second cantilever. The conductive contact head is disposed on the second conductive block, and the second conductive block is connected to the power interface through the cable assembly.

[0012] According to some embodiments of the present invention, the second conductive block is insulatedly connected to the rotary table via an L-shaped connecting block.

[0013] According to some embodiments of the present invention, the first connecting edge of the connecting block is detachably mounted on the rotating base by means of an insulating fastener, and the second conductive block is detachably mounted on the second connecting edge of the connecting block by means of an insulating fastener.

[0014] According to some embodiments of the present invention, a second insulating pad is sandwiched between the first connecting edge of the connecting block and the rotating seat, and a third insulating pad is sandwiched between the second connecting edge of the connecting block and the second conductive block.

[0015] According to some embodiments of the present invention, the support is provided with a first stop block and the rotating base is provided with a second stop block, the first stop block and the second stop block cooperating to restrict the conductive contact head from contacting the support surface.

[0016] According to some embodiments of the present invention, the cable assembly includes a connecting sleeve, a first secondary cable, a second secondary cable, and a fourth insulating pad. The first secondary cable has a first electrical connection terminal, which is sleeved on the connecting sleeve. The first secondary cable is electrically connected to the first conductive block and the power interface. The second secondary cable has a second electrical connection terminal, which is sleeved on the connecting sleeve. The second secondary cable is electrically connected to the second conductive block and the power interface. The fourth insulating pad is sleeved on the connecting sleeve and is located between the first electrical connection terminal and the second electrical connection terminal.

[0017] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and some of these additional aspects and advantages will become apparent from the description or may be learned by practice of the invention. Attached Figure Description

[0018] Figure 1 This is a first-view structural schematic diagram of an automatic puppet welding system according to an embodiment of the present invention. Figure 2 This is a second-view structural schematic diagram of an automatic puppet welding system according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the puppet welding clamp from a first-view perspective in one embodiment of the present invention. Figure 4 This is a schematic diagram of the puppet welding clamp from a second perspective in one embodiment of the present invention; Figure 5 This is a schematic diagram of the support structure in one embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of the rotary table in one embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the connecting block in one embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of the first conductive block in one embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of an insulating fastener according to an embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of the first stop block in one embodiment of the present invention; Figure 11 This is a schematic diagram of the structure of the second stop block in one embodiment of the present invention; Figure 12 This is a schematic diagram of the cable assembly in one embodiment of the present invention; Explanation of key component symbols: Power supply box 100, clamping fixture 200, puppet welding clamp 300, driver 310, fixed arm 320, support 321, first cantilever 3211, first conductive block 322, support surface 323, first insulating pad 324, movable arm 330, rotating seat 331, second conductive block 332, conductive contact head 333, workpiece 400, connecting block 500, first connecting edge 510, second connecting edge 520, second insulating pad 530, third insulating pad 540, insulating bushing 610, insulating ring 620, first stop block 700, protrusion 710, second stop block 800, groove 810, cable assembly 900, connecting sleeve 910, first auxiliary cable 920, first electrical connection terminal 921, second auxiliary cable 930, second electrical connection terminal 931, fourth insulating pad 940; The following detailed description, in conjunction with the accompanying drawings, will further illustrate the present invention. Detailed Implementation

[0019] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0020] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0021] In the description of this invention, "multiple" refers to two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features or their sequential relationship.

[0022] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0023] Reference Figures 1 to 12 As shown, an automatic puppet welding system according to an embodiment of the present invention includes a power supply box 100, a clamping fixture 200, a robot (not shown in the figures), a puppet welding clamp 300, and a control unit.

[0024] Specifically, the power supply box 100 is provided with a power interface (not shown in the figure), and the clamping fixture 200 is provided with a positioning part (not shown in the figure) and a clamping part (not shown in the figure). The robot is used to transfer the workpiece 400 onto the clamping fixture 200 and to transfer the welded workpiece 400 off the clamping fixture 200.

[0025] During operation, the positioning unit positions the unwelded workpiece 400 transferred by the robot on the worktable of the clamping fixture 200, while the clamping unit stably fixes the workpiece 400 on the worktable to prepare for subsequent welding.

[0026] For example, the clamping fixture 200 is equipped with a clamping cylinder and a position sensor, both of which are connected to the control unit. When the positioning unit positions the unwelded workpiece 400 transferred by the robot onto the worktable on the clamping fixture 200, the position sensor detects the position signal and feeds it back to the control unit, which then controls the clamping cylinder to clamp the workpiece 400.

[0027] The puppet welding clamp 300 has a driver 310, a fixed arm 320, and a movable arm 330. When the driver 310 is in operation, it drives the movable arm 330 to move, causing the movable arm 330 to move away from and closer to the fixed arm 320. The fixed arm 320 has a first conductive part connected to a power interface via a cable assembly 900. The first conductive part has a support surface 323 that matches the shape of the welding position on the workpiece 400. For example, if the welding position on the workpiece 400 is a plane, a support surface of corresponding size is provided on the first conductive part to ensure good contact between the support surface and the welding position on the workpiece 400, while preventing excessive contact stress from leaving welding indentations during welding. The movable arm 330 has a second conductive part connected to a power interface via the cable assembly 900. The second conductive part has an arc-shaped conductive contact head 333. The end of the arc-shaped conductive contact head 333 ensures that the welding point does not spread outside the welding area on the workpiece 400, thereby ensuring welding quality.

[0028] The control unit is used to control the power supply box 100 to output electrical energy from the power interface according to preset welding parameters, and to control the robot and the puppet welding clamp 300 to perform corresponding actions. For example, the welding parameters include the output voltage and the impedance of the welding circuit.

[0029] In this embodiment, when it is necessary to weld the workpiece 400, the controller controls the driver 310 to drive the movable arm 330 closer to the fixed arm 320 until the workpiece 400 at the welding position is clamped between the support surface 323 and the conductive contact head 333; after the workpiece 400 is welded, the controller controls the driver 310 to drive the movable arm 330 away from the fixed arm 320 until the movable arm 330 no longer obstructs the picking up and taking down of the workpiece 400.

[0030] It should be noted that the power supply box 100 and the clamping fixture 200 are existing technologies and will not be described in detail here.

[0031] In some embodiments of the present invention, the control unit may be a control device with programmable functionality, such as a PLC control module or an MCU control module.

[0032] In some embodiments of the present invention, such as Figures 3 to 5As shown, the fixed arm 320 includes a support 321 and a first conductive block 322. Specifically, the support 321 is fixedly mounted on the clamping fixture 200 by fasteners. The support 321 is provided with a first cantilever 3211. The first conductive block 322 is insulated at the extended end of the first cantilever 3211. A support surface 323 is formed on the surface of the first conductive block 322. The first conductive block 322 is connected to a power interface through a cable assembly 900.

[0033] Preferably, in order to reduce the impedance of the welding circuit, the first conductive block 322 is made of a metal with good conductivity, such as copper.

[0034] In some embodiments of the present invention, such as Figure 3 As shown, in order to ensure the insulating connection between the first conductive block 322 and the first cantilever 3211, a first insulating pad 324 is sandwiched between the first cantilever 3211 and the first conductive block 322.

[0035] Alternatively, the first insulating pad 324 may be made of insulating bakelite.

[0036] In some embodiments of the present invention, such as Figure 3 As shown, the first conductive block 322 is detachably mounted on the first cantilever 3211 using insulating fasteners. This detachable mounting facilitates the replacement of any damaged or malfunctioning first conductive block 322. Furthermore, to prevent current flowing through the first conductive block 322 from leaking into the support 321, the first conductive block 322 and the first cantilever 3211 are secured using insulating fasteners. Optionally, the insulating fasteners can be insulating bushings 610, which are then locked in place by insulating rings 620.

[0037] To ensure the structural strength of the insulating fasteners, the main bodies of the insulating bushing 610 and the insulating ring 620 can be made of insulating bakelite, and the outer surfaces of the insulating bushing 610 and the insulating ring 620 can also be made of insulating bakelite.

[0038] In some embodiments of the present invention, such as Figure 3 , Figure 4 , Figure 6 As shown, the movable arm 330 includes a rotating base 331 and a second conductive block 332. Specifically, the rotating base 331 is rotatably connected to the support 321, and the driver 310 is drively connected to the rotating base 331. When the driver 310 is in the working state, the driver 310 drives the movable arm 330 to rotate on the support 321, causing the movable arm 330 to move away from and closer to the fixed arm 320.

[0039] Optionally, the driver 310 can be a power device such as a cylinder or a motor. For example, the driver 310 is a cylinder, and the extension rod of the cylinder is rotatably connected to the rotary seat 331. Further, the cylinder seat of the cylinder is fixedly connected to the support 321 by fasteners to fix the cylinder on the clamping fixture 200.

[0040] The support 321 is provided with a second cantilever, the second conductive block 332 is insulatedly disposed at the extended end of the second cantilever, the conductive contact head 333 is disposed on the second conductive block 332, and the second conductive block 332 is connected to the power interface through the cable assembly 900.

[0041] Preferably, in order to reduce the impedance of the welding circuit, the second conductive block 332 is made of a metal with good conductivity, such as copper.

[0042] When making electrical connections, the second conductive block 332 can be connected to the positive terminal of the power interface through the cable assembly 900, and the first conductive block 322 can be connected to the negative terminal of the power interface through the cable assembly 900. In this way, the power box 100, the first conductive block 322, and the second conductive block 332 can form a welding circuit.

[0043] In some embodiments of the present invention, such as Figure 3 As shown, the second conductive block 332 is insulatedly connected to the rotating base 331 via an L-shaped connecting block 500. This allows for the adaptation to different workpieces 400 or different welding positions by replacing the connecting blocks 500 with different sizes. At the same time, the insulation design prevents the current flowing through the second conductive block 332 from leaking to the connecting block 500 and the rotating base 331.

[0044] In some embodiments of the present invention, such as Figure 7 As shown, the connecting block 500 has a first connecting edge 510 and a second connecting edge 520 that are perpendicular to each other. The first connecting edge 510 is detachably mounted on the rotating base 331 by means of an insulating fastener, and the second conductive block 332 is detachably mounted on the second connecting edge 520 of the connecting block 500 by means of an insulating fastener. Optionally, the insulating fastener can be an insulating bushing 610, which is locked by an insulating ring 620. Furthermore, to ensure the structural strength of the insulating fastener, the main bodies of both the insulating bushing 610 and the insulating ring 620 can be made of insulating bakelite, and the outer surfaces of both the insulating bushing 610 and the insulating ring 620 can also be made of insulating bakelite.

[0045] In some embodiments of the present invention, in order to achieve insulation between the second conductive block 332, the connecting block 500, and the rotating base 331, such as Figure 3As shown, a second insulating pad 530 is sandwiched between the first connecting edge 510 of the connecting block 500 and the rotating seat 331, and a third insulating pad 540 is sandwiched between the second connecting edge 520 of the connecting block 500 and the second conductive block 332.

[0046] Optionally, the second insulating pad 530 may be made of insulating bakelite, and the third insulating pad 540 may also be made of insulating bakelite.

[0047] In some embodiments of the present invention, such as Figure 4 , Figure 10 , Figure 11 As shown, the support 321 is provided with a first stop 700, the top of the first stop 700 is provided with a protrusion 710, the rotating seat 331 is provided with a second stop 800, the bottom of the second stop 800 is provided with a groove 810. When the protrusion 710 is fully inserted into the groove 810, the rotating seat 331 cannot rotate toward the support 321 side, so as to avoid the conductive contact head 333 from directly contacting the support surface 323 and damaging the conductive contact head 333.

[0048] In some embodiments of the present invention, such as Figure 12 As shown, the cable assembly 900 includes a connecting sleeve 910, a first auxiliary cable 920, a second auxiliary cable 930, and a fourth insulating pad 940.

[0049] Specifically, the first auxiliary cable 920 has a first electrical connection terminal 921, which is sleeved on the connecting sleeve 910. The first auxiliary cable 920 electrically connects the first conductive block 322 and the power interface. The second auxiliary cable 930 has a second electrical connection terminal 931, which is sleeved on the connecting sleeve 910. The second auxiliary cable 930 electrically connects the second conductive block 332 and the power interface. A fourth insulating pad 940 is sleeved on the connecting sleeve 910 and is located between the first electrical connection terminal 921 and the second electrical connection terminal 931. This can prevent a short circuit between the first auxiliary cable 920 and the second auxiliary cable 930, which could damage the power supply box 100.

[0050] Alternatively, the fourth insulating pad 940 may be made of insulating bakelite, and the insulating bushing 610 may also be made of insulating bakelite.

[0051] In summary, this invention overcomes the inherent defects of existing puppet welding technology in terms of spatial adaptability, welding quality (surface concavity), and automation level through innovative structural design (especially the combination of shape-matching support surface and arc contact head) and control coordination of robot and control unit. It achieves high-quality, high-efficiency, and high-safety automated welding in narrow spaces and is suitable for fields such as automobile manufacturing that have stringent requirements for workpiece appearance and automated production.

[0052] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. An automatic puppet welding system characterized by, The utility model relates to a welding robot system, which comprises: a power supply box provided with a power supply interface; a clamping tool provided with a positioning part and a clamping part, the positioning part is used for positioning a workpiece, and the clamping part is used for clamping a preset position of the workpiece after the workpiece is positioned; a robot used for transferring the workpiece into the clamping tool and transferring the welded workpiece out of the clamping tool; a dummy welding electrode holder having a driver, a fixed arm and a movable arm, the driver drives the movable arm away from and close to the fixed arm, the fixed arm is provided with a first conductive part connected with the power supply interface through a cable assembly, the first conductive part is provided with a supporting surface matched with a welding position on the workpiece, the movable arm is provided with a second conductive part connected with the power supply interface through the cable assembly, the second conductive part is provided with a circular arc-shaped conductive contact head, when the fixed arm and the movable arm are close to the preset position, the welding position on the workpiece is clamped between the supporting surface and the conductive contact head; a control unit used for controlling the power supply box to output electric energy from the power supply interface according to preset welding parameters and controlling the robot and the driver to perform corresponding actions.

2. The automatic puppet welding system of claim 1, wherein, The fixed arm comprises: a support fixedly arranged on the clamping tool, the support is provided with a first cantilever arm; a first conductive block insulatively arranged at an extending end of the first cantilever arm, the supporting surface is formed on a surface of the first conductive block, and the first conductive block is connected with the power supply interface through the cable assembly.

3. The automatic puppet welding system of claim 2, wherein, A first insulating pad is arranged between the first cantilever arm and the first conductive block.

4. The automatic puppet welding system according to claim 2 or 3, characterized in that, The first conductive block is detachably arranged on the first cantilever arm through an insulating fastener.

5. The automatic puppet welding system of claim 2, wherein, The movable arm comprises: a rotating seat rotationally connected with the support, the driver is transmissionally connected with the rotating seat, and the support is provided with a second cantilever arm; a second conductive block insulatively arranged at an extending end of the second cantilever arm, the conductive contact head is arranged on the second conductive block, and the second conductive block is connected with the power supply interface through the cable assembly.

6. The automatic puppet welding system of claim 5, wherein, The second conductive block is insulatively connected with the rotating seat through an L-shaped connecting block.

7. The automatic puppet welding system of claim 6, wherein, A first connecting edge of the connecting block is detachably arranged on the rotating seat through an insulating fastener, and the second conductive block is detachably arranged on a second connecting edge of the connecting block through an insulating fastener.

8. The automatic puppet welding system of claim 7, wherein, A second insulating pad is arranged between the first connecting edge of the connecting block and the rotating seat, and a third insulating pad is arranged between the second connecting edge of the connecting block and the second conductive block.

9. The automatic puppet welding system of claim 5, wherein, A first stop block is arranged on the support, a second stop block is arranged on the rotating seat, and the first stop block and the second stop block are matched to limit the conductive contact head from contacting the supporting surface.

10. The automatic puppet welding system of claim 5, wherein, The cable assembly comprises: a connecting sleeve; a first sub-cable provided with a first electric connection terminal, the first electric connection terminal is sleeved on the connecting sleeve, and the first sub-cable is electrically connected with the first conductive block and the power supply interface; a second sub-cable provided with a second electric connection terminal, the second electric connection terminal is sleeved on the connecting sleeve, and the second sub-cable is electrically connected with the second conductive block and the power supply interface; and a fourth insulating pad sleeved on the connecting sleeve and located between the first electric connection terminal and the second electric connection terminal.

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