Stud welding tool and stud welding method applying same

Abstract

The invention discloses a stud welding tool and a stud welding method applying the same. The tool comprises a rack, a telescopic supporting unit, a stud welding gun and a detection unit, the rack is provided with a lower mounting table and an upper mounting table, and the telescopic supporting unit is arranged on the lower mounting table and comprises a telescopic connecting rod capable of ascending and descending, a top supporting block and a movable plate capable of ascending and descending synchronously; the stud welding gun is connected to the upper mounting table through a lifting mechanism, and a welding head of the stud welding gun is coaxial with the supporting block; an upper detection probe and a lower detection probe of the detection unit are used for detecting the upper position and the lower position of the movable plate respectively, and after the upper detection probe detects the movable plate, a lifting mechanism of the stud welding gun can execute the descending action. The supporting function is transferred to the tool body, the structural design of the gripping apparatus is greatly simplified, the research, development, manufacturing and maintenance cost of the gripping apparatus is reduced, and universality and remodeling efficiency are improved; and through accurate positioning and signal feedback of the detection unit, efficient linkage of the tool, a manipulator and a control system is guaranteed, and the welding failure rate and the defective rate are reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile part processing, in particular to a stud welding tool and a stud welding method using the same. BACKGROUND

[0002] In the traditional stud welding process, the support structure is generally added to the gripper to realize the operation. This mode has many outstanding defects: the structure design needs to be accurately matched with the gripper, resulting in poor tool versatility, and the gripper and support components need to be simultaneously modified when changing the vehicle model, which takes a long time to adapt; on the equipment cost level, the development, manufacturing and maintenance costs of customized grippers and support structures are high, which greatly increases the production investment; on the production efficiency, frequent tool debugging and model changing operations seriously slow down the flow line rhythm and restrict the capacity improvement. SUMMARY

[0003] The present application aims to solve the technical problems existing in the related art, and proposes a stud welding tool that discards the dependence on the gripper support structure and realizes stable operation through optimized structure design.

[0004] The stud welding tool according to the first aspect of the present application comprises: a rack provided with a lower mounting table and an upper mounting table; a telescopic support unit provided on the lower mounting table, the telescopic support unit being provided with a telescopic connecting rod that can be raised and lowered, the upper end of the telescopic connecting rod being provided with a support block; the telescopic connecting rod is connected with a movable plate, and the movable plate is raised and lowered synchronously with the telescopic connecting rod; a stud welding gun connected with the upper mounting table through a lifting mechanism, the stud welding gun being raised and lowered through the lifting mechanism; the lower end of the stud welding gun is provided with a welding head, and the welding head is coaxially arranged with the support block; a detection unit provided with an upper detection probe and a lower detection probe, the upper detection probe and the lower detection probe being used to detect the upper and lower positions of the movable plate respectively, and the lifting mechanism of the stud welding gun can only perform a lowering action after the upper detection probe detects the movable plate.

[0005] The stud welding tool according to the present application has at least the following beneficial effects: 1. This technology transfers the support function to the tool body, greatly simplifies the structure design of the gripper, reduces the development, manufacturing and maintenance costs of the gripper, and avoids the simultaneous modification of the gripper and support components when changing the vehicle model, thereby significantly improving the tool versatility and model changing efficiency; 2. Through the accurate positioning and signal feedback of the detection unit, the efficient linkage of the tool, the robot and the control system is ensured, the welding failure rate and the defective rate are reduced, and the stability and reliability of the welding process are improved.

[0006] According to some embodiments of the present application, the support block has a conical platform structure, the conical surface of which faces upward, and the top surface of the support block is provided with a tumor discharge groove extending along the radial direction of the support block.

[0007] According to some embodiments of the present application, the support block is a component made of chromium-zirconium-copper material, and the support block is detachably connected with the telescopic connecting rod through a threaded structure.

[0008] According to some embodiments of the present application, the telescopic support unit comprises a telescopic cylinder, a fixing seat and an insulating pad, the insulating pad is arranged between the fixing seat and the lower mounting table, the telescopic cylinder is fixedly connected with the fixing seat and the lower mounting table, and the telescopic connecting rod is connected with the piston rod of the telescopic cylinder.

[0009] According to some embodiments of the present application, the insulating pad is a component made of cloth-filled ebonite, which is used to block the conduction of welding current to the lower mounting table.

[0010] According to some embodiments of the present application, the movable plate has a bending structure, and the bending part of the movable plate moves between the upper detection probe and the lower detection probe.

[0011] According to some embodiments of the present application, the upper detection probe and the lower detection probe are both proximity switches, and the movable plate is a metal component.

[0012] According to the stud welding method of the second aspect of the embodiments of the present application, the stud welding tool is used, and the method comprises the following steps: S10. When the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tool, the telescopic support unit extends the support block upward until the upper detection probe detects the movable plate, at which time the first welding position of the workpiece is positioned and supported by the support block; S20. The upper detection probe feeds back an extension-to-position signal to the control system, and then the control system issues a welding instruction to control the lifting mechanism to drive the stud welding gun to move downward until the welding head of the stud welding gun abuts against the first welding position of the workpiece, and then the stud welding gun starts welding operation; S30. After the first welding position of the workpiece is completed, the stud welding gun is reset upward under the driving of the lifting mechanism, and the telescopic support unit is reset downward until the lower detection probe detects the movable plate. S40. The lower detection probe feeds back a reset-to-position signal to the control system, and then the manipulator adjusts the posture and moves the next welding position of the workpiece to the preset welding position of the stud welding tool, the telescopic support unit extends the support block upward until the upper detection probe detects the movable plate again. S50. Repeating steps S20 to S40 until all welding positions of the workpiece are completed.

[0013] The stud welding method according to the third aspect of the present application, using the stud welding tooling described above, comprises the following steps: S100. When the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tooling, the telescopic support unit extends the support block upward until the upper detection probe detects the movable plate, at which time the first welding position of the workpiece is positioned and supported by the support block; S200. The upper detection probe feeds back an extension-to-position signal to the control system, and then the control system issues a welding instruction to control the lifting mechanism to move the stud welding gun downward until the welding head of the stud welding gun abuts against the first welding position of the workpiece, and then the stud welding gun starts welding operation; S300. After the first welding position of the workpiece is completed, the stud welding gun is reset upward under the driving of the lifting mechanism, and the position of the telescopic support unit remains unchanged, and then the manipulator adjusts the posture and moves the next welding position of the workpiece to the preset welding position of the stud welding tooling and completes the positioning and support with the support block; S400. Repeating steps S200 to S300 until all welding positions of the workpiece are completed; S500. After all welding positions of the workpiece are completed, the stud welding gun is reset upward under the driving of the lifting mechanism, and the telescopic support unit is reset downward until the lower detection probe detects the movable plate.

[0014] According to some embodiments of the present application, in step S300, an adjustment space is formed between the support block and the reset welding head, the height of the adjustment space is greater than the thickness of the workpiece, and the horizontal range of the adjustment space is greater than the movement track range of the manipulator in switching the welding position of the workpiece.

[0015] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 is a perspective structural schematic view of the stud welding tooling provided by the embodiments of the present application when the support block is extended upward; Figure 2 is a perspective structural schematic view of the stud welding tooling provided by the embodiments of the present application when the support block is reset downward; Figure 3is a perspective structural schematic view of the telescopic supporting unit provided by the embodiment of the present application; Figure 4 is a perspective structural schematic view of the detection unit provided by the embodiment of the present application.

[0017] In the drawings: 100 - rack, 110 - leveling foot, 120 - lower mounting table, 130 - upper mounting table, 140 - stand column, 200 - telescopic supporting unit, 300 - stud welding gun, 210 - telescopic cylinder, 220 - fixed seat, 230 - insulating pad, 240 - telescopic connecting rod, 250 - supporting block, 251 - deflating groove, 260 - movable plate, 270 - clamping block, 261 - bending part, 400 - detection unit, 410 - upper detection probe, 420 - lower detection probe, 430 - connecting support, 440 - mounting plate, 450 - reinforcing rib, 500 - lifting mechanism, 310 - welding head. DETAILED DESCRIPTION

[0018] The embodiments of the present application are described in detail below, examples of which are shown in the drawings, wherein the same or similar notations represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary only, for the purpose of explaining the present application, and should not be understood as a limitation of the present application.

[0019] In the description of the present application, it should be understood that the orientation description, such as the orientation or position relationship indicated by up, down, front, back, left, right, etc. is based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be understood as a limitation of the present application.

[0020] In the description of the present application, the meaning of several is one or more, and the meaning of multiple is more than two, greater than, less than, more than, etc. are understood as not including the number, and above, below, etc. are understood as including the number. If it is described as first, second, it is only for the purpose of distinguishing technical features, and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated or the order of technical features indicated.

[0021] In the description of the present application, unless otherwise explicitly limited, the words such as setting, mounting, connecting, etc. should be understood in a broad sense, and the person skilled in the art can reasonably determine the specific meaning of the above words in the present application in combination with the specific content of the technical solution.

[0022] The stud welding tool disclosed by the application is characterized in that the support function is transferred from the traditional grabber to the tool body through integrated structure design, precise positioning, stable support and efficient cooperation in the welding process are realized, and the technical defects of poor tool versatility, high cost and low efficiency in the traditional process are completely solved. The specific structure, connection relationship and function realization of each component are described in detail from the rack 100 in the following order from bottom to top, ensuring that the design logic of each component is highly consistent with the overall technical scheme, and ensuring the stable and reliable operation of the tool in the automatic production scene.

[0023] As shown in Figure 1 and Figure 2 , the rack 100 is the installation basis and bearing body of the entire tool, made of high-strength Q235B steel. This material has excellent mechanical strength and rigidity, can effectively resist the vibration, impact force and high temperature generated during welding, and avoid deformation or displacement of the rack 100, providing a firm and reliable platform for the installation of subsequent functional components. Since the stud welding tool is a link in the automatic production line, the size of the rack 100 needs to adapt to the layout requirements of the automatic production line, and be flexibly fixed and adjusted according to the actual situation of the production site.

[0024] The bottom of the rack 100 is provided with a plurality of leveling feet 110, which adopt a threaded structure of M24 specification. By rotating the leveling feet 110, the horizontal adjustment of the rack 100 can be realized, ensuring that the rack 100 can still maintain a horizontal state under the condition that the ground surface of the production site is uneven, and avoiding the welding position from being offset due to the inclination of the rack 100.

[0025] The rack 100 is clearly divided into a lower mounting table 120 and an upper mounting table 130. The lower mounting table 120 is located below the upper mounting table 130, and the upper mounting table 130 is located at the top of the rack 100. Both the lower mounting table 120 and the upper mounting table 130 are assembled on the column 140 of the rack 100, ensuring that there is no relative displacement between the mounting table and the rack 100, and the connection rigidity is sufficient. The upper surface of the lower mounting table 120 is milled, with a flatness error controlled within 0.02mm, providing a high-precision reference surface for the installation of the telescopic support unit 200; the surface of the upper mounting table 130 is also milled, providing a high-precision reference surface for the installation of the stud welding gun 300.

[0026] As shown in Figures 1 to 3As shown, the telescopic support unit 200 is the core component of the tooling, responsible for providing precise and stable support for the workpiece during welding, replacing the fixed support structure on the traditional gripper. The telescopic support unit 200 is located on the upper surface of the lower mounting table 120, and includes a telescopic cylinder 210, a fixed seat 220, an insulating pad 230, a telescopic connecting rod 240, and a support block 250. Each component cooperates to realize the up-down movement of the support block 250.

[0027] The fixed seat 220 is integrally cast from HT200 gray cast iron, which has good rigidity and wear resistance, providing a stable installation base for the telescopic cylinder 210. The bottom of the fixed seat 220 is provided with four M16 mounting holes, which are fixedly connected to the upper surface of the lower mounting table 120 by high-strength bolts. The tightening torque of the bolts is controlled at 50-60 N / m to ensure that the fixed seat 220 and the lower mounting table 120 are not loose. The fixed seat 220 is connected to the telescopic cylinder 210 by bolts, and the insulating pad 230 is arranged between the fixed seat 220 and the lower mounting table 120. The insulating pad 230 can be made of cloth-wood, which has excellent insulation performance, mechanical strength, and high-temperature resistance. It can effectively block the conduction of welding current to the lower mounting table 120 during welding, preventing current leakage from damaging other electrical components of the tooling and preventing the operator from being electrocuted by touching the rack 100. The thickness of the insulating pad 230 is 10 mm, and the size is equivalent to the bottom profile of the fixed seat 220. It is provided with four through holes corresponding to the mounting holes of the fixed seat 220 to ensure that the bolts can smoothly pass through the insulating pad 230 and fasten the fixed seat 220. The upper and lower surfaces of the insulating pad 230 are polished to a surface roughness Ra≤1.6 μm to ensure a tight fit with the fixed seat 220 and the lower mounting table 120, preventing arcing due to poor contact.

[0028] The telescopic cylinder 210 is the power source of the telescopic support unit 200. Its cylinder body is fixedly connected to the fixed seat 220 by bolts. The piston rod of the telescopic cylinder 210 is fixedly connected to the telescopic connecting rod 240 by a threaded structure. The end of the piston rod is provided with an M20 external thread, and the lower end of the telescopic connecting rod 240 is provided with a corresponding internal thread. After tightening, they are locked by a lock nut to prevent loosening due to vibration during welding. The telescopic connecting rod 240 is made of 45# steel after quenching and tempering treatment, with a hardness of HRC28-32, which has good strength and toughness, and can withstand the axial pressure applied by the welding gun and the reaction force of the workpiece during welding. The top of the telescopic connecting rod 240 is also provided with an M16 external thread for detachable connection with the support block 250, facilitating replacement and maintenance of the support block 250.

[0029] The support block 250 is a key part directly in contact with the workpiece and providing a supporting force, and its performance directly determines the stability of the workpiece and the welding quality during the welding process. Therefore, the structure design and material selection are optimized according to the process characteristics of stud welding. The support block 250 is preferably made of chromium-zirconium-copper material. Chromium-zirconium-copper is a copper alloy with high strength, high conductivity and high temperature resistance. Its tensile strength is ≥450 MPa, electrical conductivity is ≥75% IACS, and hardness is ≥HB140. It can maintain structural stability in a high-temperature welding environment, effectively offset the force applied by the welding gun, avoid workpiece deformation, and at the same time has good wear resistance, prolonging the service life of the part.

[0030] The support block 250 has a conical table structure with a conical surface facing upwards. The conical angle of the conical table is designed to be 60°. This angle has been verified through multiple tests and can guide the workpiece to be welded to automatically fit the axis of the support block 250 through the force component of the contact point. Even if there is a small deviation of ±0.5 mm in the positioning of the robot, it can be corrected through the guiding action of the conical table surface, ensuring that the stud welding gun 300, the stud, and the support block 250 are coaxial, avoiding the problems of virtual welding and offset welding caused by welding deviation. The top surface of the support block 250 is provided with a slag groove 251. The slag groove 251 is a one-letter structure extending through the radial direction of the support block 250. The groove width is 3 mm, and the groove depth is 5 mm. This size design can ensure that the molten slag and spatter generated during welding can be discharged into the groove or outside the tooling in a timely manner, avoiding the accumulation of waste slag between the support surface and the workpiece, causing the support surface to be uneven and the welding current to be unstable, and thus causing defects such as welding bumps and slag inclusion. At the same time, the presence of the slag groove 251 can also increase the heat dissipation area of the top of the support block 250, forming an air convection channel to accelerate the dissipation of heat during welding, prevent the support block 250 from deforming due to temperature accumulation, and also prevent the workpiece from deforming due to local overheating.

[0031] The telescopic support unit 200 also includes a movable plate 260. The movable plate 260 has a bending structure and is made of Q235 steel plate with a thickness of 5 mm, which has good rigidity. One end of the movable plate 260 is fixed on the bottom of the telescopic connecting rod 240 through a clamping block 270, and rises and falls synchronously with the telescopic connecting rod 240. The other end is bent downward to form a bent part 261. At this time, the height position of the bent part 261 is lower than the height position of the telescopic connecting rod 240. This arrangement has the advantage of reducing the setting height of the subsequent detection unit 400, reducing the occurrence of interference, and saving costs. The surface of the movable plate 260 is sprayed with anti-rust paint after rust removal treatment to prevent rusting during long-term use and affecting detection accuracy.

[0032] AsFigure 1 、 Figure 2 and Figure 4 As shown in FIGS. 4A and 4B, the detection unit 400 is a "perception center" that ensures the cooperation of various components of the tool. By accurately detecting the position state of the movable plate 260, the position state of the support block 250 is indirectly obtained, and key signals are fed back to the control system to realize the action linkage of the stud welding gun 300 and the support block 250. The detection unit 400 is provided with an upper detection probe 410 and a lower detection probe 420. The upper detection probe 410 is located above the lower detection probe 420. Both the upper detection probe 410 and the lower detection probe 420 can be selected as a proximity switch, for example, a proximity switch of TL-N5ME1 type. The proximity switch is an inductive non-contact switch with a detection distance of 5 mm, a response time ≤1 ms, and advantages of high detection precision, strong anti-interference ability, and long service life. The proximity switch can accurately capture the position signal of the movable plate 260 and feed back to the control system. Both the upper detection probe 410 and the lower detection probe 420 are NPN type output, which is adapted to the I / O interface of the control system. When the bent part 261 of the movable plate 260 is detected, a low-level signal is output. When the bent part 261 of the movable plate 260 is not detected, a high-level signal is output.

[0033] In addition, the detection unit 400 further includes a connecting bracket 430 and a mounting plate 440. The connecting bracket 430 is made of Q235 steel plate and is formed by bending. The connecting bracket 430 has a stepped structure and is provided with a reinforcing rib 450 in the vertical direction. The connecting bracket 430 is fixed to the lower mounting table 120 by four M10 bolts. The top surface of the connecting bracket 430 is provided with the upper detection probe 410 penetrating through the connecting member. At this time, the detection direction of the upper detection probe 410 is downward. The middle part of the connecting bracket 430 is connected with the mounting plate 440. The mounting plate 440 has an L-shaped structure. The mounting plate 440 is provided with the lower detection probe 420 penetrating through the connecting member. At this time, the detection direction of the lower detection probe 420 is toward the upper detection probe 410. The bent part 261 of the movable plate 260 of the telescopic support unit 200 moves between the upper detection probe 410 and the lower detection probe 420, so that the upper detection probe 410 and the lower detection probe 420 can detect the upper and lower positions of the movable plate 260, respectively, and then detect the upper and lower positions of the support block 250 to accurately capture the telescopic state of the telescopic support unit 200.

[0034] When the telescopic support unit 200 extends the support block 250 upward, the upper detection probe 410 detects the bent part 261 of the movable plate 260 in real time. Once the upper detection probe 410 detects the bent part 261 of the movable plate 260, the upper detection probe 410 is triggered and sends a “extended to position” signal to the control system. After the control system receives the signal, the lifting mechanism 500 of the stud welding gun 300 can perform the descending action, ensuring that the workpiece is always in a stable support state during the welding process. When the telescopic support unit 200 resets the support block 250 downward, the lower detection probe 420 detects the bent part 261 of the movable plate 260 in real time. Once the lower detection probe 420 detects the bent part 261 of the movable plate 260, the lower detection probe 420 is triggered and sends a “reset to position” signal to the control system. After the control system receives the signal, the robot can adjust the posture or move the workpiece to avoid interference between parts. That is, the setting height of the upper detection probe 410 and the lower detection probe 420 is positively correlated with the upper and lower limit height of the support block 250, so the limit height of the support block 250 can be adjusted by adjusting the setting height of the detection probe or adjusting the position of the movable plate 260.

[0035] As shown in Figure 1 and Figure 2 The stud welding gun 300 is used as an execution component for realizing stud welding. It is connected to the upper mounting table 130 through the lifting mechanism 500, ensuring that the stud welding gun 300 can be precisely lifted to avoid interference. The stud welding gun 300 selects a BS315 capacitor energy storage type welding gun, which has the advantages of stable welding current, fast welding speed, and convenient operation, and is suitable for stud welding of diameter 3-8mm, which can meet the requirements of the beat of the automatic production line. The lower end of the stud welding gun 300 is provided with a welding head 310 made of chromium zirconium copper material, which is consistent with the material of the support block 250, ensuring stable conduction of the welding current. The end of the welding head 310 is provided with a clamping structure adapted to the stud, which can firmly clamp the stud and ensure that the axis of the stud coincides with the axis of the welding head 310. The studs used for welding can be provided by a vibrating disc + blowing mechanism. The vibrating disc arranges and conveys multiple studs in the same direction to the blowing mechanism, which blows multiple studs one by one to the feeding port of the stud welding gun 300 through compressed air. The welding head 310 is coaxially arranged with the support block 250, and the coaxiality error is controlled within 0.03mm, ensuring that the stud can be accurately aligned with the welding position of the workpiece during welding, avoiding welding deviation.

[0036] The lifting mechanism 500 is used to drive the stud welding gun 300 to realize up and down movement, and the lifting mechanism 500 includes but is not limited to a pneumatic cylinder, an electric push rod or a linear motor. When the control system issues a welding instruction, the lifting mechanism 500 drives the stud welding gun 300 to move downward until the welding head 310 abuts against the welding position of the workpiece, and the pressure detection is used to avoid the welding head 310 or the workpiece from being damaged; after the welding is completed, the lifting mechanism 500 drives the stud welding gun 300 to reset upward, so as to reserve sufficient space for replacement or movement of the workpiece.

[0037] The control system of the tooling can be selected as a PLC, the control system receives the position signals of the upper detection probe 410 and the lower detection probe 420 through a digital input module, controls the actions of the telescopic cylinder 210 and the lifting mechanism 500 through a digital output module, and simultaneously realizes signal interaction with the controller of the manipulator through a communication interface, so as to ensure orderly implementation of the entire welding process. The control system is also provided with a touch screen for parameter setting, state monitoring and fault alarm, and an operator can set parameters such as welding current and welding time through the touch screen, and can view the working states of each component in real time. When a fault such as failure of support in place or abnormal detection signal occurs, the touch screen displays a fault code, so that the operator can timely troubleshoot.

[0038] The embodiment of the application also provides two stud welding methods, and the overall working process of the tooling is described in detail below in combination with the two specific stud welding methods, and the cooperative working logic of each component is further described.

[0039] The first stud welding method is a conventional beat working mode, and is suitable for a scene with a small number of studs and general beat requirements, and the specific working process is as follows: S10, after the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tooling, the controller of the manipulator sends a "workpiece in place" signal to the control system of the tooling. After receiving the signal, the control system issues a control instruction to control the telescopic cylinder 210 of the telescopic support unit 200 to be aerated, the piston rod is extended upward, and the telescopic connecting rod 240, the support block 250 and the movable plate 260 are synchronously lifted. During the lifting process, the bent part 261 of the movable plate 260 gradually approaches the upper detection probe 410, and when the support block 250 is lifted to completely support the workpiece, the bent part 261 of the movable plate 260 enters the detection range of the upper detection probe 410, the upper detection probe 410 is triggered and feeds back a "extended in place" signal to the control system.

[0040] S20, after the control system receives the above signals, it sends a welding instruction after a delay of 0.02s, on the one hand, it controls the lifting mechanism 500 to work, so that it drives the stud welding gun 300 to move downward until the welding head 310 abuts against the first welding position of the workpiece; on the other hand, it controls the stud welding gun 300 to start welding operation, the welding current is conducted to the workpiece through the welding head 310, the stud, and then to the ground through the support block 250, forming a welding loop, and the stud is fused with the workpiece under the action of high temperature and high pressure.

[0041] S30, after the welding time ends, the stud welding gun 300 stops welding, the control system sends a reset instruction to control the lifting mechanism 500 to drive the stud welding gun 300 to reset upward, so that the stud welding gun 300 returns to the initial position; then, the extension cylinder 210 of the telescopic support unit 200 is exhausted, the piston rod resets downward, driving the support block 250, the telescopic connecting rod 240 and the movable plate 260 to descend synchronously. When the bent part 261 of the movable plate 260 descends to the detection range of the lower detection probe 420, the lower detection probe 420 triggers and feeds back a "reset in place" signal to the control system.

[0042] S40, after the control system receives the above signals, it sends a "first welding position completed" signal to the controller of the manipulator, then the manipulator adjusts the posture and moves the next welding position of the workpiece to the preset welding position of the stud welding tool, the telescopic support unit 200 extends the support block 250 upward until the upper detection probe 410 detects the bent part 261 of the movable plate 260 again.

[0043] S50, repeat steps S20 to S40 until all welding positions of the workpiece are completed. After the welding is completed, the manipulator carries the workpiece out of the tool area and enters the next production process, the control system controls the components to reset and waits for the next welding process.

[0044] The second welding method is a high-efficiency beat mode, which is suitable for scenes with a large number of studs and high beat requirements, and the specific working process is as follows: S100, after the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tool, the controller of the manipulator sends a "workpiece in place" signal to the control system of the tool. After receiving the signal, the control system sends a control instruction to control the extension cylinder 210 of the telescopic support unit 200 to exhaust, the piston rod extends upward, driving the telescopic connecting rod 240, the support block 250 and the movable plate 260 to ascend synchronously. During the ascending process, the bent part 261 of the movable plate 260 gradually approaches the upper detection probe 410, when the support block 250 ascends to completely support the workpiece, the bent part 261 of the movable plate 260 enters the detection range of the upper detection probe 410, the upper detection probe 410 triggers and feeds back a "extended in place" signal to the control system.

[0045] S200, after the control system receives the above signals, it sends a welding instruction after a delay of 0.02s. On the one hand, it controls the lifting mechanism 500 to work, so that it drives the stud welding gun 300 to move downward until the welding head 310 abuts against the first welding position of the workpiece; on the other hand, it controls the stud welding gun 300 to start welding operation, and the welding current is conducted to the workpiece through the welding head 310, the stud, and then to the ground through the support block 250, forming a welding loop, and the stud is fused with the workpiece under the action of high temperature and high pressure.

[0046] S300, after the welding time ends, the stud welding gun 300 stops welding, and the control system sends a reset instruction to control the lifting mechanism 500 to drive the stud welding gun 300 to reset upward, so that the stud welding gun 300 returns to the initial position. At the same time, the position of the telescopic support unit 200 remains unchanged, and the control system sends a "switchable station" signal to the manipulator, so that the manipulator does not need to wait for the telescopic support unit 200 to reset, but directly adjusts the posture to drive the next welding position of the workpiece to move above the corresponding support block 250 and complete the support positioning. In this process, an adjustment space is formed between the support block 250 and the reset welding head 310, the height of the adjustment space is greater than the thickness of the workpiece, and the horizontal range of the adjustment space is greater than the movement track range of the workpiece switched by the manipulator, so as to ensure that the manipulator does not interfere with the support block 250 or the stud welding gun 300 when adjusting the posture.

[0047] S400, repeat steps S200 to S300 until all welding positions of the workpiece are completed. Since the position of the telescopic support unit 200 remains unchanged, the upper detection probe 410 is always in the triggered state, and it continuously feeds back the "extended to position" signal to the control system.

[0048] S500, after all welding positions of the workpiece are completed, the stud welding gun 300 moves upward to the initial position under the drive of the lifting mechanism 500, the telescopic cylinder 210 of the telescopic support unit 200 is exhausted, and the piston rod resets downward to drive the support block 250, the telescopic connecting rod 240 and the movable plate 260 to descend synchronously. When the bent part 261 of the movable plate 260 descends to the detection range of the lower detection probe 420, the lower detection probe 420 is triggered and feeds back a "reset to position" signal to the control system. The control system sends a "operation completed" signal to the manipulator, and the manipulator carries the workpiece out of the tooling area and enters the next production process.

[0049] The tooling completely abandons the design idea of setting a support structure on the side of the grabber in the traditional process through the precise design and cooperative work of the above-mentioned components, and transfers the support function to the tooling body, which brings multiple significant technical effects: first, the structure design of the grabber is greatly simplified, the traditional grabber needs to design a complex support structure for different workpieces, while the grabber of the tooling only needs to realize the clamping and carrying function of the workpiece, without the need to additionally set a support component, which reduces the research and development, manufacturing and maintenance cost of the grabber, and avoids the synchronous modification of the grabber and the support component when the model is changed, the change type cycle is shortened from 3-5 days of the traditional process to 4-8 hours, which significantly improves the tooling universality and change type efficiency; second, through the precise linkage of the detection unit 400 and each execution component, it is ensured that the workpiece is always in a stable support state during welding, the coaxial design of the welding head 310 and the support block 250 avoids welding deviation, the welding qualified rate is improved from 95% of the traditional process to more than 99.5%, which greatly reduces the welding failure rate and the defective rate; third, the integrated structure integration design makes the tooling perfectly adapt to the layout requirements of the automatic production line, the design of the two working modes can flexibly cope with different production requirements, especially in the high-efficiency rhythm mode, the more the number of welded studs is, the more significant the rhythm saving effect is, for example, for a workpiece with 10 welded studs, it takes 60s in the conventional rhythm working mode, but only 30s in the high-efficiency rhythm mode, the production efficiency is obviously improved; fourth, the design of the insulating pad 230 effectively blocks the leakage of the welding current, which guarantees the safety of the equipment and the personal safety of the operator, the support block 250 is made of chrome zirconium copper material and is provided with a vent groove 251, which prolongs the service life of the component and reduces the maintenance cost.

[0050] The embodiments of the application are described in detail above in combination with the drawings, but the application is not limited to the above-mentioned embodiments, and various changes can be made within the knowledge range of ordinary skilled persons in the technical field without departing from the purpose of the application.

Claims

1. A stud welding fixture, characterised in that, The utility model relates to a stud welding tool, comprising: a rack provided with a lower mounting table and an upper mounting table; a telescopic supporting unit provided on the lower mounting table, the telescopic supporting unit being provided with a telescopic connecting rod capable of ascending and descending, the upper end of the telescopic connecting rod being provided with a supporting block, the telescopic connecting rod being connected with a movable plate, the movable plate ascending and descending synchronously with the telescopic connecting rod; a stud welding gun connected with the upper mounting table through a lifting mechanism, the stud welding gun ascending and descending through the lifting mechanism, the lower end of the stud welding gun being provided with a welding head coaxially arranged with the supporting block; a detection unit provided with an upper detection probe and a lower detection probe, the upper detection probe and the lower detection probe being respectively used for detecting the ascending and descending positions of the movable plate, the lifting mechanism of the stud welding gun being capable of descending only after the upper detection probe detects the movable plate.

2. The stud welding fixture of claim 1, wherein: The supporting block has a conical table structure, the conical surface of which faces upward, the top surface of the supporting block being provided with a tumor discharge groove extending along the radial direction of the supporting block.

3. The stud welding fixture of claim 1 or 2, wherein: The supporting block is a component made of chromium-zirconium-copper material, the supporting block and the telescopic connecting rod being detachably connected through a threaded structure.

4. The stud welding fixture of claim 1, wherein: The telescopic supporting unit comprises a telescopic cylinder, a fixing seat and an insulating pad, the insulating pad being arranged between the fixing seat and the lower mounting table, the telescopic cylinder being fixedly connected with the lower mounting table through the fixing seat, the telescopic connecting rod being connected with the piston rod of the telescopic cylinder.

5. The stud welding fixture of claim 4, wherein: The insulating pad is a veneer-bonded ebonite component, used for blocking the conduction of welding current to the lower mounting table.

6. The stud welding fixture of claim 1, wherein: The movable plate has a bending structure, the bending part of the movable plate moving between the upper detection probe and the lower detection probe.

7. The stud welding fixture of claim 1, wherein: The upper detection probe and the lower detection probe are both proximity switches, the movable plate being a metal component.

8. A stud welding method characterised by, The stud welding tool is applied, comprising the following steps: S10. After the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tool, the telescopic supporting unit extends the supporting block upward until the upper detection probe detects the movable plate, at which time the first welding position of the workpiece is positioned and supported by the supporting block; S20. The upper detection probe feeds back an extension-to-position signal to the control system, then the control system issues a welding instruction to control the lifting mechanism to drive the stud welding gun to move downward until the welding head of the stud welding gun abuts against the first welding position of the workpiece, and then the stud welding gun starts welding work; S30. After the first welding position of the workpiece is completed, the stud welding gun is reset upward under the driving of the lifting mechanism, and the telescopic supporting unit is reset downward until the lower detection probe detects the movable plate; S40. The lower detection probe feeds back a reset-to-position signal to the control system, then the manipulator adjusts the posture and moves the next welding position of the workpiece to the preset welding position of the stud welding tool, the telescopic supporting unit extends the supporting block upward until the upper detection probe detects the movable plate again; S50. Steps S20 to S40 are repeated until all the welding positions of the workpiece are completed.

9. A stud welding method characterised by, The stud welding tooling as claimed in any one of claims 1 to 7, comprising the following steps: S100. When the manipulator moves the first welding position of the workpiece to the preset welding position of the stud welding tooling, the telescopic support unit extends the support block upward until the upper detection probe detects the movable plate, at which time the first welding position of the workpiece is supported and positioned by the support block; S200. The upper detection probe feeds back an extension-to-position signal to the control system, and then the control system issues a welding instruction to control the lifting mechanism to move the stud welding gun downward until the welding head of the stud welding gun abuts against the first welding position of the workpiece, and then the stud welding gun starts the welding operation; S300. After the first welding position of the workpiece is completed, the stud welding gun is reset upward under the driving of the lifting mechanism, the position of the telescopic support unit remains unchanged, then the manipulator adjusts the posture and moves the next welding position of the workpiece to the preset welding position of the stud welding tooling and completes the support positioning with the support block; S400. Repeat steps S200 to S300 until all welding positions of the workpiece are completed; S500. After all welding positions of the workpiece are completed, the stud welding gun is reset upward under the driving of the lifting mechanism, and the telescopic support unit is reset downward until the lower detection probe detects the movable plate.

10. The stud welding method of claim 9, wherein: In step S300, an adjustment space is formed between the support block and the reset welding head, the height of the adjustment space is greater than the thickness of the workpiece, and the horizontal range of the adjustment space is greater than the movement track range of the manipulator driving the workpiece to switch the welding position.

Images