Full-automatic welding and polishing production line for aluminum veneers

Abstract

A full-automatic welding and grinding production line for aluminum veneers comprises a control system, a feeding and transferring robot, a feeding positioner, an automatic laser welding robot, a welding positioning workbench, an automatic upender, an automatic grinding robot, a grinding positioning workbench, a grinding automatic tool changer, a grinding dust removal room and a transferring and discharging robot. The control system is mounted on the console; the feeding and transferring robot and the feeding positioner are installed in the feeding and transferring area. The automatic laser welding robot and the welding positioning workbench are installed on the laser welding station. The automatic upender is mounted in the upending area; the automatic polishing robot, the polishing positioning workbench, the polishing automatic tool changer and the polishing dust removal room are installed on the polishing work station. The transferring and discharging robot is installed in the transferring and discharging area. According to the full-automatic aluminum veneer welding and polishing production line, a traditional aluminum veneer welding and polishing production process is changed, and existing production equipment is combined with automatic model selection and upgrading, so that the full-automatic aluminum veneer welding and polishing production line is formed.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of aluminum veneer full-automatic welding polishing production line, belongs to aluminum veneer production process technical field. BACKGROUND

[0002] Aluminum veneer is a kind of building decoration material, it has public welfare good, corrosion resistance, high strength, easy to clean, recycling and many other characteristics.Aluminum veneer production is made by punching, bending, assembling, welding, polishing and other processes to raw materials, aluminum veneer is processed into the shape and size required.Welding and polishing process are difficult to produce, high technical requirements, slow processing efficiency and harmful substances or dust particles in the production process harm worker's health.

[0003] Because aluminum veneer belongs to non-standard custom-made piece, the shape and size of each aluminum veneer are different, resulting in aluminum veneer production and turnover need to rely on a large number of production personnel.Welding and polishing process are low in automation, and production process, quality and efficiency are greatly dependent on worker's skill level and experience.

[0004] How to improve the automation level, efficiency and quality of aluminum veneer welding and polishing process is particularly important. SUMMARY

[0005] The purpose of the present application is to solve the problem of aluminum veneer welding and polishing process, which is difficult to produce, high technical requirements, slow processing efficiency and harmful substances or dust particles in the production process harm worker's health, improve the automation level of aluminum veneer welding and polishing process, and propose a kind of aluminum veneer full-automatic welding polishing production line.

[0006] The technical solution realized by the present application is as follows, a kind of aluminum veneer full-automatic welding polishing production line, the equipment of the production line includes control system, feeding and transfer robot, feeding positioner, automatic laser welding robot, welding positioning workbench, automatic material turning machine, automatic polishing robot, polishing positioning workbench, polishing automatic tool changer, polishing dust removal room, transfer and unloading mechanical robot;All equipment of aluminum veneer welding and polishing automation production is installed on aluminum veneer full-automatic welding polishing production line;The production line is a set of system integrating aluminum veneer automatic feeding, transfer, welding and polishing.

[0007] The control system adopts a self-developed welding and grinding software platform with a built-in new speed look-ahead algorithm, which can automatically smooth corner speeds and accurately coordinate the timing and force of actions. An electronic control system is configured for the automatic laser welding robot. The electronic control system and the control system are deeply integrated with built-in motion control algorithm and vibration suppression algorithm. The motion control algorithm can accurately coordinate the timing of actions between various devices and ensure high path accuracy under high-speed operation. The vibration suppression algorithm can minimize the vibration generated by the arc welding robot during movement, ensuring a smooth, accurate and fast welding process.

[0008] The aluminum single-panel welding and grinding production line includes a control console, a feeding and transfer area, a laser welding station, a turning area, a grinding workstation, and a transfer and unloading area according to the production process flow. The control system is installed on the control console. The feeding and transfer robot and the feeding positioner are installed in the feeding and transfer area. The automatic laser welding robot and the welding positioning workbench are installed in the laser welding station. The automatic turning machine is installed in the turning area. The automatic grinding robot, the grinding positioning workbench, the automatic grinding tool changer, and the grinding dust removal room are installed in the grinding workstation. The transfer and unloading robot is installed in the transfer and unloading area.

[0009] The control system includes a computer, a PLC programmable logic controller, a memory, a data bus, and control software. It centrally controls and integrates servo drives, Modbus TCP protocol communication, and an industrial tablet human-machine interface to issue commands and collect information for the entire production line. Adopting a modular approach, it debugs each production piece by process, integrating each process into a unit modular architecture. The control system then uses these unit modules to achieve efficient collaborative management of each process and piece of equipment. The control system supports both automatic and manual (maintenance) modes. Automatic mode achieves fully automated operation according to preset protocol logic, while manual mode allows for individual motor control for debugging or maintenance. The production line features unit activation permission management; unactivated equipment cannot be operated. It is equipped with a dual human-machine interface: a computer and an industrial tablet. The main interfaces of both the computer and industrial tablet display the equipment's operating status, work orders, counts, and other production data, along with menu navigation and operation guidance. When equipment malfunctions, system alarm information is displayed on the screen, and diagnostic functions are provided to allow operators to quickly restore production. Frequently used functions are located on the auxiliary buttons of the industrial tablet, allowing for quick operation without navigating the touchscreen. The computer can compile programs and retrieve production data. The PLC sends instructions to the execution units via a high-speed bus, ensuring precise and controllable production rhythm. A deep safety interlock mechanism is integrated, including emergency stop buttons and alarm devices, ensuring the safety of equipment and operators. An industrial IoT interface is also reserved for factory data acquisition and remote monitoring.

[0010] An automatic grinding robot is equipped with a force-controlled grinding system. This system and control system work in deep collaboration, incorporating a built-in force-controlled grinding algorithm. It features automatic tool changing and detection functions, as well as gravity compensation, ensuring that the grinding force applied to the workpiece surface by the robot remains equal to the set value regardless of its spatial posture. The control system not only allows editing of welding and grinding parameters but also provides real-time monitoring and recording of specific data for each production run, ensuring that parameters and quality throughout the entire process are storable, traceable, and copyable. The control system programming employs a combination of graphical import and parameter editing, supporting one-click generation of welding and grinding paths from graphical imports and programming of welding and grinding parameters. The control system provides… It offers a rich material library and welding / grinding process solution library, and provides advanced editing functions such as batch modification and array copying; the control system provides work order management, supporting manual input or automatic generation of work order numbers by time. Work orders need to be bound to parameter templates and include information such as production quantity, planned start time, and estimated completion time. Successfully created work orders are displayed in the work order list, sorted by planned start time by default; workers can drag and drop to prioritize production, and it supports querying data such as production time, completion time, and completed quantity by work order number; it receives information on successful but incomplete orders and displays them in list format, displaying all incomplete orders for the day by default, and supports sorting by planned start time and priority.

[0011] The loading and transfer robot includes a six-axis robotic arm, a vacuum suction cup, a ground rail, and a loading positioner. The robot is responsible for loading and transferring aluminum panels. The six-axis robotic arm is mounted on the ground rail and its movement is driven by the rail. The ground rail is controlled by the six-axis robotic arm's teach-program program and connected to its built-in controller, facilitating the picking and placing of aluminum panels of various sizes. The robot uses a vacuum suction cup to pick up the panels and has a panel presence detection function. The panel-separating gripper on the robot, in conjunction with the brush on the loading positioner, can separate materials into sheets, and multiple sheets are detected by a detector to avoid affecting the equipment. The loading positioner positions the panels, and the robot picks them up. When picking up panels, the robot requires that the incoming materials be neatly stacked, of unique type, and in a unique direction. The loading positioner is equipped with a detector that alarms when there is no material.

[0012] The automated laser welding robot includes a ground rail, an arc welding robot, an automatic torch cleaning and wire cutting device, and a laser guiding system. The arc welding robot is mounted on the ground rail, the automatic torch cleaning and wire cutting device is mounted on the base of the arc welding robot, and the laser guiding system is mounted next to the welding torch of the arc welding robot arm.

[0013] The arc welding robot includes a six-axis robotic arm, anti-collision sensors, an electronic control system, a welding power source, a wire feeder, a welding torch, a shielding gas supply unit, and a ground rail. The arc welding robot is equipped with anti-collision sensors that provide flexible anti-collision functionality, maximizing the safety of the equipment and operators. The arc welding robot uses a ground rail to drive the six-axis robotic arm in reciprocating motion. The six-axis robotic arm's precise positioning of the welding position allows for flexible adjustment of the welding torch's posture and position to adapt to different welding positions and trajectories. The arc welding robot's electronic control system and overall control system work in deep collaboration, incorporating motion control and vibration suppression algorithms. The motion control algorithm ensures high path accuracy even at high speeds, while the vibration suppression algorithm ensures continued welding accuracy even at high speeds.

[0014] The electrical control system includes a control cabinet, servo drive, I / O interface module, welding power supply, and communication interface; the servo drive, I / O interface module, welding power supply, and communication interface are located inside the control cabinet. The electrical control system uses an internal and external dual-circulation design to achieve a high IP54 protection rating. The welding power supply and welding torch employ the latest push-pull wire spatter-free transition welding process, which reduces spatter by more than 90% compared to traditional gas shielded welding. The ultra-low heat input welding process reduces heat input by 50% compared to traditional gas shielded welding, effectively reducing thermal deformation and weld defects. It has superior gap bridging capability. The electrical control system can receive signals from the laser system in real time; collect and control welding process parameters such as the current and voltage of the welding power supply and the wire feeder's wire feed speed, and feed them back to the control system. The control system tracks the weld seam and adjusts its posture in real time based on the feedback information during the welding process, and dynamically adjusts the welding parameters to ensure the stability of the welding process and the consistency of welding quality.

[0015] The laser guidance system includes a laser emitter, a laser receiver target, a prism, and a controller. Installed next to the welding gun of the arc welding robot, the system guides the robot to a designated position along a preset path, precisely directing it to the welding location for welding. In addition to identifying the welding position, the laser guidance system can also monitor the weld condition and penetration depth in real time, feeding the results back to the control system. The control system then dynamically adjusts and compensates based on this feedback, improving welding quality.

[0016] The automatic torch cleaning and wire cutting device includes a torch cleaning and wire cutting mechanism, a material receiving assembly, and a controller. The automatic torch cleaning and wire cutting device is mounted on the base of the arc welding robot and moves with the robot, ensuring its relative position remains constant, facilitating the robot's constant torch cleaning. It removes welding slag from the inner wall of the torch, addresses issues such as excessively short or long welding wires, or spherical ends, and improves welding quality. It features wire cutting, oil removal, slag removal, and nozzle surface polishing functions. The controller controls the operation of the torch cleaning and wire cutting mechanism.

[0017] The welding positioning workbench includes a closed-loop electric cylinder centering transmission positioning servo and a pneumatic clamping fixture. After the aluminum plate is transported to the workbench by the loading and transfer robot, centering is completed by the closed-loop electric cylinder centering transmission positioning servo, and the pneumatic fixture clamps it in place. The positioning workbench uses a steel structure with fireproof and heat-insulating panels on the surface to ensure the equipment's load-bearing capacity and prevent deformation and scorching of the surface during long-term use. The closed-loop electric cylinder centering transmission positioning servo receives signals from the system for centering and positioning, while a displacement sensor detects the workpiece dimensions; an alarm is triggered if the deviation is greater than 0.5mm. The positioning servo uses a closed-loop electric cylinder, which features high precision, high dynamic response, and strong anti-interference capabilities. Under the same conditions, it can repeatedly achieve high-precision positioning, ensuring the consistency of the production process and the stability of product quality.

[0018] The automatic material turning machine includes a side-pushing mechanism, a vacuum suction cup gripper, and a limit stop. The automatic material turning machine is installed on a roller conveyor line at the bottom; the limit stop is installed at the tail end, the side-pushing mechanism is installed on the side of the conveyor line, and the vacuum suction cup gripper is installed at the lower end of the conveyor line; the roller conveyor line has a frequency converter with five speed settings; the product is transported along the conveyor line to the bottom and contacts the limit stop. Simultaneously, a sensor inside the limit stop detects the equipment, triggering the side-pushing mechanism to push the product to one side of the vacuum suction cup gripper. The vacuum suction cup gripper picks up the product and lifts it up, and subsequently, a transfer and unloading robot picks it up to complete the turning action.

[0019] The grinding robot comprises a six-axis robotic arm, protective clothing, a cable package, a force-controlled grinding system, and a ground rail. The force-controlled grinding system includes a force-position compensator and dual electric grinding heads. The grinding robot features buoyancy control, ensuring the contact force between the grinding head and the workpiece is always equal to a set value, unaffected by workpiece dimensional errors, robot posture, or abrasive wear, achieving high-quality grinding. The grinding robot uses a ground rail to drive the six-axis robotic arm in reciprocating motion. The six-axis robotic arm's precise positioning of the grinding position allows for flexible adjustment of the grinding head's posture and position to adapt to different grinding positions and trajectories. The robotic arm's transmission mechanism uses high-precision RV and harmonic reducer drives, resulting in minimal mechanical attenuation. The grinding robot is externally encased in a protective clothing and cable package, providing dust and flame retardancy. The force-controlled grinding system and control system of the grinding robot are deeply integrated with a built-in force-controlled grinding algorithm, ensuring that the grinding pressure applied to the workpiece surface by the grinding head is always equal to the set value under any spatial posture. The force-position compensator and the dual electric grinding heads are mounted together on the six-axis robotic arm. The force-position compensator adjusts the grinding pressure of the grinding head in real time to ensure that it is always equal to the set value, and collects grinding information to feed back to the control system. The force-position compensator uses a closed-loop feedback control method to adjust and maintain a constant grinding pressure.

[0020] The force-position compensator includes a sensing unit, an execution unit, a rotation unit, and a control unit. The sensing unit is a force sensor installed between the grinding head and the spindle to detect the normal force between the grinding head and the workpiece in real time. The execution unit uses a cylinder to drive the spindle to achieve telescopic movement. The rotation unit uses a servo motor to drive the spindle to rotate via a coupling. The control unit completes data acquisition, algorithm calculation, and command output. When the detected difference in normal force between the grinding head and the workpiece is less than a threshold, the compensator's execution mechanism quickly adjusts: the controller adjusts the output force of the cylinder, and the spindle slides within the bearing seat to achieve flexible floating of the grinding head. The working process of the force-position compensator is as follows: the control unit receives the force value → the sensor collects the actual contact force in real time → the error value is calculated → the controller determines the adjustment scheme → the spindle or robot posture is adjusted → the compensation data is recorded → re-detection. The threshold refers to the limit value of the adjustment range of the force-position compensator.

[0021] The control system collects, records, and saves grinding information, facilitating subsequent tracking and analysis of specific data from each grinding session. The dual-electric grinding head has two grinding spindles: one set for grinding the louvers and the other for sandpaper grinding, which can be switched at any time according to grinding needs.

[0022] The welding positioning workbench includes a length-width direction centering clamping positioning servo, a dust collector, and a workbench. After the product is transferred to the workbench, the length-width direction centering clamping positioning servo performs centering and clamping in both the length and width directions. The workbench is made of steel to ensure the load-bearing capacity of the equipment and prevent deformation during long-term use. The clamping positioning servo receives signals from the system to perform centering and clamping. The positioning servo uses a closed-loop electric cylinder, which has high precision, high dynamic response, and strong anti-interference ability. Under the same conditions, it can repeatedly achieve high-precision positioning, ensuring the consistency of the production process and the stability of product quality. The dust collector is located at the bottom of the workbench and has a dust collection function, which can collect grinding dust into the dust collector; reducing the dispersion of grinding dust and its impact on equipment operation.

[0023] The automatic grinding tool changer adopts a sheet metal frame structure, which is durable and not easily deformed. This automatic grinding tool changer can store enough grinding discs for more than two hours of continuous use. It includes a louvered tool magazine and a sandpaper magazine, each with its own independent storage and supply system. Consumables can be automatically replaced according to system settings. The supply mechanisms of both tool magazines are equipped with presence sensors to detect whether consumables have been successfully replaced, and an alarm prompts for replenishment when the number of consumables falls below ten. The automatic grinding tool changer is equipped with an automatically opening and closing dust cover to ensure the interior of the tool magazine is clean and prevent grinding disc contamination.

[0024] The grinding dust removal chamber includes a dust removal room and a dust removal device. The dust removal room adopts a frame-type sheet metal welded body, with profile welding on the sides and top. Ventilation is achieved through louvers at the top, and dust is extracted from the bottom. A dust collector is located below the welding positioning workbench and connected to a dust extraction pipe with good sealing, ensuring a negative pressure state inside the dust removal room when the roller shutter door is closed, preventing dust from overflowing. An automatic roller shutter door with its operating switch is located on the side of the transfer and unloading robot, with a manual door at the rear equipped with a safety lock. The automatic roller shutter door is connected to the control system for automatic opening and closing, and can also be unlocked for manual operation. The automatic grinding robot, grinding positioning workbench, and automatic grinding tool changer are installed inside the chamber. The dust removal chamber has good dust removal efficiency and is connected to the external dust removal device. The chamber adopts a sealed structure, and the dust removal device extracts dust through the internal dust collector and dust extraction ports on the bottom side. Air is introduced through the louvers at the top, and the negative pressure state inside the dust removal chamber ensures effective dust extraction. The dust removal device adopts a wet filtration scheme, with an internal spray layer, two layers of filter media, a large-diameter air intake, and a water shortage alarm. The internal dust removal spray system uses filter balls and is equipped with a silencer to reduce noise pollution. It also uses an explosion-proof centrifugal fan and an explosion-proof control box.

[0025] The transfer and unloading robot includes a six-axis robotic arm, a vacuum suction cup, and a floor rail. The robot is responsible for flipping, transferring, and unloading aluminum panels. The six-axis robotic arm is mounted on the floor rail, which is controlled by the robotic arm's teach-program program and connected to its built-in controller, facilitating the picking and placing of aluminum panels of various sizes. The robot uses a vacuum suction cup to pick up the panels and has a panel presence detection function.

[0026] The programming route for the fully automatic welding and grinding process of aluminum single panels in this invention is as follows: Power on (control console) → Open program editor → Enter program name → Import graphic (or enter size parameters, welding and grinding points, etc.) → Set welding process parameters (material, thickness, welding method, etc.) → Set grinding process parameters (grinding method, pressure, range, roughness, etc.) → Complete programming (system automatically records).

[0027] The fully automated welding and grinding process for aluminum panels of this invention is as follows: manual start-up (control console settings and work order selection) → AGV feeding → loading and transfer robot (loading to laser welding station) → laser welding station (welding of corners and reinforcing ribs to folded edges) → loading and transfer robot (transferring to flipping area) → automatic flipping machine (flipping aluminum panels) → transfer and unloading robot (picking up flipped aluminum panels and placing them into grinding workstation) → grinding workstation (grinding weld feet and panel surface) → transfer and unloading robot (automatic unloading) → AGV picking up material.

[0028] The beneficial effects of this invention are as follows: By changing the traditional aluminum panel welding and grinding manufacturing process, and combining existing production equipment with automated selection, modification, upgrading, and configuration, a fully automated aluminum panel welding and grinding production line is formed. The grinding robot of this invention has a buoyancy control function, ensuring that the contact force between the grinding head and the workpiece is always equal to the set value, unaffected by workpiece size errors, robot posture, or abrasive wear, thus achieving high-quality grinding. The six-axis robotic arm of this invention's arc welding robot precisely positions the welding location, allowing for flexible adjustment of the welding gun's posture and position to adapt to different welding positions and trajectories. After the production line of this invention is put into operation, compared to traditional production lines, the number of workers is reduced from 12 to 1-2, and the annual production capacity increases from 280,000 square meters to 400,000 square meters, representing a 42.9% increase in capacity. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the layout of the fully automated aluminum single-panel welding and grinding production line of the present invention; Figure 2 This is a schematic diagram of the equipment layout of the control console on the fully automated aluminum single-panel welding and grinding production line of the present invention; Figure 3 This is a schematic diagram of the equipment layout for the loading and transfer robot of the present invention; Figure 4 This is a schematic diagram of the equipment layout of the laser welding station of the present invention; Figure 5 This is a schematic diagram of the equipment layout of the automatic material turning machine of the present invention; Figure 6 This is a schematic diagram of the equipment layout of the grinding workstation of the present invention; Figure 7 This is a schematic diagram of the equipment layout for the transfer and unloading robot of the present invention; In the diagram, 1 is the control console; 2 is the loading and transfer area; 3 is the laser welding station; 4 is the material turning area; 5 is the grinding workstation; 6 is the transfer and unloading area; 11 is the computer; 12 is the control system; 21 is the loading and transfer robot; 22 is the loading positioner; 31 is the automatic laser welding robot; 32 is the welding positioning worktable; 41 is the automatic material turning machine; 42 is the side pushing mechanism; 43 is the vacuum suction cup gripper; 44 is the limit stop; 51 is the automatic grinding robot; 52 is the grinding positioning worktable; 53 is the automatic grinding tool changer; 54 is the grinding dust removal room; and 61 is the transfer and unloading robot. Detailed Implementation

[0030] Figure 1 The diagram shown is a layout of a fully automated aluminum panel welding and grinding production line according to this embodiment. Along the production process flow, the production line in this embodiment includes a control console 1, a feeding and transfer area 2, a laser welding station 3, a turning area 4, a grinding workstation 5, and a transfer and unloading area 6.

[0031] The loading and transfer robot 21 is installed in the loading and transfer area 2 to load and weld aluminum panels at the welding station, and then transfer them to the turning area 4; the automatic laser welding robot 31 and the welding positioning workbench 32 are installed in the laser welding station 3 to weld the edges and corners of the aluminum panels and weld the reinforcing ribs and folded edges; the automatic turning machine 41 is installed in the turning area 4 to turn the aluminum panels over; the automatic grinding robot 51, the grinding positioning workbench 52, the automatic grinding tool changer 53, and the grinding dust removal room 54 are installed in the grinding workstation 5 to grind the weld feet and the surface of the aluminum panels; the transfer and unloading robot 61 is installed in the transfer and unloading area 6 to transfer the aluminum panels from the turning machine to the grinding station and unload the aluminum panels; the welding and grinding production line is controlled by the control system according to the production process flow to achieve fully automatic production.

[0032] Figure 2 This is a schematic diagram of the equipment layout of a control console on a fully automated aluminum single-panel welding and grinding production line according to the present invention. The equipment includes a computer 11 and a control system 12, which are installed on the control console 1. The control system 12 includes a data bus, a control module, a production execution module, an industrial tablet HMI module, a programmable logic controller (PLC), and control software. The computer 11 is interconnected with each module and controller, and the control software is installed in the computer. The computer is connected to each piece of equipment on the production line via the data bus. The control system adopts a centralized architecture, integrating servo drive, Modbus TCP communication, and an industrial tablet HMI, and achieves production line equipment collaboration through modular design. It supports automatic / manual dual modes, has equipment activation permission management, and is equipped with dual interfaces of computer and industrial tablet for real-time monitoring of operating status, work order data, and alarm diagnosis. The PLC precisely controls the execution unit via a high-speed bus, integrates safety interlocking mechanisms such as emergency stop, and reserves an IoT interface. It has a built-in dedicated algorithm platform for welding and grinding: the welding robot is equipped with speed look-ahead, motion control, and vibration suppression algorithms to ensure high speed and high precision; the grinding robot is equipped with a force control system, supports automatic tool changing and gravity compensation, and ensures constant grinding pressure. Programming supports both graphical import and parameter editing modes, and includes a built-in material and process database. Work order management supports multi-task editing, drag-and-drop sorting, and automatic switching, with full traceability of production data.

[0033] Figure 3The diagram shown illustrates the equipment layout of a feeding and transfer robot on a fully automated aluminum panel welding and grinding production line according to this embodiment. The production equipment includes a feeding and transfer robot 21 and a feeding positioner 22, installed in the feeding and transfer area 2. The feeding and transfer robot 21 includes a six-axis robotic arm, a vacuum suction cup, a floor rail, and the feeding positioner 22. The six-axis robotic arm and the floor rail work together to grasp and transfer aluminum panels through teach-in programming control. The vacuum suction cup picks up the panels, and the sheet-separating gripper, brush, and detector complete the sheet-separating and multi-sheet detection. The feeding positioner positions the panels and alarms when there is no material. The incoming materials must be neatly stacked and of the same type and orientation.

[0034] Figure 4 The diagram shows the equipment layout of the laser welding station on a fully automated aluminum panel welding and grinding production line according to this embodiment. The production equipment includes an automatic laser welding robot 31 and a welding positioning worktable 32, which are installed at the laser welding station 3.

[0035] The automated laser welding robot 31 includes a ground rail, an arc welding robot, an automatic torch cleaning and wire cutting device, and a laser system. The arc welding robot arm is mounted on the ground rail, the automatic torch cleaning and wire cutting device is mounted on the base of the arc welding robot, and the laser system is mounted next to the welding torch of the arc welding robot.

[0036] The arc welding robot includes a six-axis robotic arm, an electrical control system, a welding power source, a wire feeder, a welding torch, a shielding gas supply unit, and a ground rail. Equipped with anti-collision sensors, the robot utilizes the ground rail and six-axis robotic arm for precise positioning. The electrical control system and the overall control system work in deep collaboration, incorporating motion control and vibration suppression algorithms to achieve high-speed, high-precision welding with an IP54 protection rating. The welding power source employs new technologies such as push-pull wire welding with no spatter and ultra-low heat input, exhibiting strong gap bridging capabilities. The electrical control system can receive laser signals in real time and dynamically adjust welding parameters to ensure stable welding processes and consistent quality.

[0037] The laser system includes a laser emitter, a laser receiver target, a prism, and a controller. The laser system is installed next to the welding torch. After the robot reaches the preset position, it precisely guides the welding process and monitors information such as weld seam and penetration depth in real time. This information is then fed back to the control system for dynamic adjustments and compensation to improve welding quality.

[0038] The automatic torch cleaning and wire cutting device includes a torch cleaning and wire cutting mechanism, a material receiving assembly, and a controller. The automatic torch cleaning and wire cutting device is installed on the arc welding robot base and moves with it, maintaining a constant relative position to clean the welding torch at any time. It has functions of wire cutting, oil removal, slag removal, and nozzle grinding, which can remove welding slag and handle welding wire abnormalities, thereby improving welding quality.

[0039] The welding positioning workbench 32 includes a closed-loop electric cylinder centering transmission positioning servo and a pneumatic clamping fixture. After the loading and transfer robot transfers the aluminum plate to the workbench, the positioning servo completes the centering, and the pneumatic clamping fixture clamps it in place. The workbench uses a steel structure and fireproof heat insulation panels to ensure load-bearing capacity without deformation or burning. The positioning servo receives signals from the system for centering, and the displacement sensor detects the dimensions; an alarm is triggered if the deviation exceeds 0.5mm. The closed-loop electric cylinder provides high precision, high response, and anti-interference capabilities, allowing for repeated and accurate positioning to ensure production consistency and stable quality.

[0040] Figure 5 The diagram shows the equipment layout of an automatic material turning machine on a fully automated aluminum single-panel welding and grinding production line according to this embodiment. The production equipment includes an automatic material turning machine 41, installed in the turning area 4. The automatic material turning machine includes a side pushing mechanism 42, a vacuum suction cup gripper 43, and a limit stop 44. The automatic material turning machine is integrated into the bottom of a five-speed variable frequency roller conveyor. The product is transported by the conveyor to the bottom and contacts the limit stop. At the same time, the sensor inside the limit stop detects the equipment and triggers the side pushing mechanism to push the product to one side of the vacuum suction cup gripper. The vacuum suction cup gripper picks up the product and lifts it up. Subsequently, the transfer and unloading robot picks up the product to complete the turning action.

[0041] Figure 6 The diagram shows the equipment layout of the grinding workstation on a fully automated aluminum panel welding and grinding production line according to this embodiment. The production equipment includes an automatic grinding robot 51, a grinding positioning worktable 52, an automatic grinding tool changer 53, and a grinding dust removal chamber 54; all of the above are installed in the grinding dust removal chamber 54 of the grinding workstation 5.

[0042] The grinding robot comprises a six-axis robotic arm, protective clothing, a pipeline package, a force-controlled grinding system, and a ground rail. The force-controlled grinding system consists of a force-position compensator, dual electric grinding heads, and a force control cabinet. The force-controlled grinding system and control system work in deep collaboration with a built-in force control algorithm. The grinding robot is flexibly positioned via the ground rail and the six-axis robotic arm, and is equipped with a high-precision reducer and dustproof, flame-retardant protective clothing. The force-position compensator adjusts in real time to maintain constant grinding pressure, unaffected by workpiece errors, posture, or abrasive wear, while simultaneously feeding data back to the control system for full recording and traceability. The dual electric grinding heads can switch between louvered blade and sandpaper modes.

[0043] The grinding and positioning worktable 52 includes a length-width aligning clamping and positioning servo, a dust collector, and a worktable. After the product is transferred to the steel structure worktable, the length-width aligning clamping and positioning servo completes the clamping and positioning. The positioning servo adopts a high-precision closed-loop electric cylinder, which has high dynamic response and anti-interference capabilities, and can repeatedly and accurately position, ensuring production consistency and quality stability. The dust collector at the bottom of the worktable collects grinding dust to avoid affecting the operation of the equipment.

[0044] The automatic grinding tool changer adopts a sheet metal frame structure and has a storage capacity for more than two hours of use. It is equipped with a louvered blade and a sandpaper dual tool magazine for independent automatic replacement. It is equipped with an in-situ sensor to monitor the replacement status and a low inventory alarm, and is equipped with an automatic opening and closing dust cover to prevent contamination.

[0045] The grinding dust collection chamber includes a dust collection room and a dust collection device. The dust collection room adopts a frame-type sheet metal welded structure, with louvered ventilation at the top and bottom dust collection. A dust collector below the workbench is connected to a sealed pipe, and negative pressure is maintained inside when the roller shutter door is closed to prevent dust overflow. It is equipped with a system-controlled automatic roller shutter door (which can also be manually operated) and a rear safety manual door. The interior houses the grinding robot, workbench, and tool changer. Wet dust collection is used, with built-in spray, filter media, filter balls, and a silencer. It is equipped with a water shortage alarm, an explosion-proof fan, and an electrical control box.

[0046] Figure 7 The diagram shows the equipment layout of a transfer and unloading robot on a fully automated aluminum panel welding and grinding production line according to this embodiment. The production equipment includes a transfer and unloading robot 61, installed in the transfer and unloading area 6. The transfer and unloading robot includes a six-axis robotic arm, a vacuum suction cup, and a floor rail. The transfer and unloading robot, composed of a six-axis robotic arm and a floor rail, is controlled by teach-in programming. It uses a vacuum suction cup to pick up the panels and has a panel detection function, responsible for the flipping, transfer, and unloading operations of the aluminum panels.

[0047] The automated manufacturing process for welding and grinding aluminum panels in this embodiment is as follows: manual start (control console settings and work order selection) → AGV feeding → loading and transfer robot (loading to the laser welding station) → laser welding station (welding of corners and reinforcing ribs to the folded edges) → loading and transfer robot (transferring to the flipping area) → automatic flipping machine (flipping the aluminum panels) → transfer and unloading robot (picking up the flipped aluminum panels and placing them into the grinding workstation) → grinding workstation (grinding the weld feet and panel surface) → transfer and unloading robot (automatic unloading) → AGV picking up materials.

Claims

1. A full-automatic welding and polishing production line for aluminum veneer, characterized in that, The equipment of the production line comprises a control system, a feeding and transfer robot, a feeding positioner, an automatic laser welding robot, a welding positioning workbench, an automatic material turning machine, an automatic polishing robot, a polishing positioning workbench, a polishing automatic tool changer, a polishing dust removal room, and a transfer and discharging robot hand; all the equipment for automatic welding and polishing of aluminum veneer is installed on the aluminum veneer automatic welding and polishing production line; the production line is a system integrating automatic feeding, transfer, welding and polishing of aluminum veneer; The control system adopts a welding and polishing software platform independently developed, has a brand-new speed foresight algorithm, can automatically round the corner speed, accurately coordinates the action time sequence and force, and is provided with an electric control system for the automatic laser welding robot; the electric control system and the control system deeply cooperate with a motion control algorithm and a vibration suppression algorithm; the motion control algorithm can accurately coordinate the action time sequence among the equipment, ensures high path precision under high-speed operation, and the vibration suppression algorithm can maximally reduce the vibration generated by the arc welding robot in motion, so that the welding process is stable, accurate and fast.

2. The full-automatic welding and polishing production line for aluminum veneer according to claim 1, characterized in that, The aluminum veneer welding and polishing production line comprises a control console, a feeding and transfer area, a laser welding station, a material turning area, a polishing work station, and a transfer and discharging area according to the production process; the control system is installed on the control console; the feeding and transfer robot and the feeding positioner are installed on the feeding and transfer area; the automatic laser welding robot and the welding positioning workbench are installed on the laser welding station; the automatic material turning machine is installed on the material turning area; the automatic polishing robot, the polishing positioning workbench, the polishing automatic tool changer, and the polishing dust removal room are installed on the polishing work station; and the transfer and discharging robot is installed on the transfer and discharging area.

3. The full-automatic welding and polishing production line for aluminum veneer according to claim 1, characterized in that, The control system comprises a computer, a PLC programmable logic controller, a memory, a data bus and a control software; the automatic polishing robot is provided with a force control polishing system; the force control polishing system and the control system deeply cooperate with a force control polishing algorithm, has automatic tool changing and detection functions, and has a gravity compensation function, so that the grinding normal pressure of the polishing robot on the workpiece surface is always equal to the set value under any spatial posture; the control system can not only edit welding and polishing parameters, but also can monitor and record specific data in real time; the force control polishing system comprises a force position compensator and a double electric polishing head; the force control polishing system and the control system deeply cooperate, the force control polishing system has a gravity compensation algorithm, can automatically calculate the gravity component of the polishing tool under different postures and compensate, and ensures force accuracy; The force-position compensator adopts a closed-loop feedback control method to adjust and maintain the grinding pressure constant: the force-position compensator comprises a sensing unit, an executing unit, a rotating unit and a control unit; the force sensor of the sensing unit is installed between the polishing head and the main shaft to detect the normal force between the polishing head and the workpiece in real time; the cylinder of the executing unit drives the main shaft to realize telescopic motion; the servo motor of the rotating unit drives the main shaft to rotate through the shaft coupling; the control unit completes data acquisition, algorithm operation and instruction output; when the normal force difference between the polishing head and the workpiece is less than the threshold value, the compensator executing mechanism is quickly adjusted: the controller adjusts the output force of the cylinder and the sliding of the main shaft in the bearing seat to realize the flexible floating of the polishing head; the working process of the force-position compensator: the control unit receives the force value → the sensor collects the actual contact force in real time → calculates the error value → the controller judges the adjustment scheme → adjusts the main shaft or the robot posture → records the compensation data → re-detects; the threshold value refers to the limit value of the adjustment range of the force-position compensator.

4. The full-automatic welding and polishing production line for aluminum veneer according to claim 1, characterized in that, The automatic laser welding robot comprises a ground rail, an arc welding robot, an automatic gun cleaning and wire cutting device and a laser guiding system; the arc welding robot is installed on the ground rail, the automatic gun cleaning and wire cutting device is installed on the base of the arc welding robot, and the laser guiding system is installed beside the welding gun of the arc welding robot; The arc welding robot comprises a six-axis robot arm, a collision avoidance sensor, an electric control system, a welding power supply, a wire feeder, an electric welding gun and a protective gas supply unit; the arc welding robot is provided with the collision avoidance sensor and has a flexible anti-collision function, which can maximize the safety of the equipment and the operator; the arc welding robot adopts the ground rail to drive the six-axis robot arm to reciprocate; the six-axis robot arm accurately positions the welding position in a movement mode, which can flexibly adjust the posture and position of the electric welding gun for welding to adapt to the requirements of different welding positions and trajectories; the electric control system and the control system of the arc welding robot are deeply coordinated, and motion control algorithm and vibration suppression algorithm are built-in; The laser guiding system comprises a laser emitting source, a laser receiving target, a prism and a controller; the laser guiding system is installed beside the electric welding gun of the arc welding robot, the arc welding robot runs to the specified position according to the preset path, and then is accurately guided to the welding position by the laser guiding system to perform the welding action; in addition to picking up the welding position, the laser guiding system can also detect the weld condition and penetration information in the welding process in real time, and feed the detection results back to the control system; the control system dynamically adjusts and compensates in real time according to the feedback information, thereby improving the welding quality; The automatic gun cleaning and wire cutting device comprises a gun cleaning and wire cutting mechanism, a material receiving assembly and a controller; the automatic gun cleaning and wire cutting device is installed on the base of the arc welding robot and moves with the arc welding robot to ensure that the relative position is unchanged and facilitate the arc welding robot to clean the welding gun at any time; the automatic gun cleaning and wire cutting device is used for removing the welding slag on the inner wall of the welding gun, processing the problem of too short, too long or spherical end of the welding wire, and improving the welding quality; the device has the functions of wire cutting, oil dipping, slag cleaning and polishing of the outer surface of the nozzle; the controller controls the work of the gun cleaning and wire cutting mechanism. The welding positioning workbench comprises a closed-loop cylinder centering transmission positioning servo and a pneumatic pressing tool clamp; the aluminum plate material is transported to the workbench by a feeding and transfer robot, the centering is completed by the closed-loop cylinder centering transmission positioning servo, and the pneumatic clamp is pressed; the positioning workbench adopts a steel structure and lays fireproof and heat insulation plates on the table top, thereby guaranteeing the bearing capacity of the equipment and preventing the table top from being deformed and burnt for a long time; the closed-loop cylinder centering transmission positioning servo receives signals from the system to perform centering positioning, a displacement sensor detects the size of the workpiece, and an alarm is given if the deviation is greater than 0.5 mm; the positioning servo adopts a closed-loop cylinder, has high precision, high dynamic response and strong anti-interference capability, and can repeatedly realize high-precision positioning under the same conditions, thereby guaranteeing the consistency of the production process and the stability of the product quality.

5. The full-automatic welding and polishing production line for aluminum veneer according to claim 1, characterized in that, The automatic turnover machine comprises a side pushing mechanism, a vacuum suction gripper and a limiting block; the automatic turnover machine is installed on a roller conveying line and located at the bottom of the conveying line; the limiting block is installed at the tail, the side pushing mechanism is installed on the side of the conveying line, and the vacuum suction gripper is installed at the lower end of the conveying line; the roller conveying line with a frequency converter has five speed regulation gears; after the product is transported to the bottom of the conveying line and stopped by the limiting block, a sensor synchronously identifies the product, the side pushing mechanism on the side of the conveying line is started to push the product to the side, the vacuum suction gripper at the bottom picks up the product to turn it over, and then the transfer and unloading manipulator picks up the lower surface to complete the turnover action.

6. The full-automatic welding and polishing production line for aluminum veneer according to claim 4, characterized in that, The electric control system comprises a control cabinet, a servo drive, an I / O interface module, a welding power source and a communication interface, the servo drive, the I / O interface module, the welding power source and the communication interface are arranged in the control cabinet; the electric control system uses double circulation design inside and outside, realizes IP54 high protection level; the welding power source and the electric welding gun adopt push-pull wire non-splashing transition welding process, the push-pull wire non-splashing transition welding reduces the splashing amount by more than 90% compared with traditional gas shielded welding; the ultra-low heat input welding process reduces the heat input amount by 50% compared with traditional gas shielded welding, effectively reduces heat deformation and leakage; has strong gap bridging capability; the electric control system receives signals from the laser system in real time, collects and controls the current and voltage of the welding power source; the wire feeding speed of the wire feeder and the welding process parameters are fed back to the control system, the control system tracks the weld and adjusts the posture in real time according to the feedback information in the welding process, and dynamically adjusts the welding parameters, thereby guaranteeing the stability of the welding process and the consistency of the welding quality.

7. The aluminum veneer full-automatic welding and polishing processing production and manufacturing process route according to claim 1: manual start, control console setting and selection of work order → AGV feeding → feeding and transfer manipulator, feeding to the laser welding station → laser welding station, welding of the connecting points of the edges, corners and reinforcing ribs and the folded edges → feeding and transfer manipulator robot, transferring the workpiece to the turnover area → automatic turnover machine, turning over the aluminum veneer → transfer and unloading manipulator, picking up the turned-over aluminum veneer and placing it into the polishing work station → polishing work station, polishing the welding feet and the plate surface → transfer and unloading manipulator, automatic unloading → AGV taking.

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