Continuous climbing type automatic welding robot for shaped steel and welding method thereof

Abstract

A kind of section steel continuous climbing automatic welding robot and welding method thereof, welding robot includes: continuous climbing mechanism, continuous climbing mechanism is installed on the outside of section steel, synchronous lifter is installed on the upper side of continuous climbing mechanism, multiple rotary drive mechanisms are movably connected on synchronous lifter by horizontal displacement mechanism, welding disc is installed on synchronous lifter, drive mechanism output end is connected with mechanical arm, mechanical hand holds welding torch, control system is connected with continuous climbing mechanism, rotary drive mechanism, synchronous lifter, horizontal displacement mechanism, welding torch, mechanical arm, mechanical hand, monitoring and identification system.This design realizes the continuous climbing of welding robot by continuous climbing mechanism, realizes the multi-surface synchronous welding of multiple welding torches by synchronous lifter, can realize the dead angle welding of welding torch in predetermined area by horizontal displacement mechanism, the angle and position of welding torch are controlled by mechanical arm, to realize the continuous welding of horizontal, vertical, oblique weld of section steel.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to a continuous climbing automatic welding robot for structural steel and its welding method. Background Technology

[0002] Modern engineering construction requires the extensive use of lightweight, high-strength steel profiles. Large building structures often require the combination of various types of steel to form a whole, and these different types of steel are usually connected by welding.

[0003] Current methods for welding structural steel typically involve technicians using handheld welding equipment to weld the upper and lower structural steel sections together after the initial butt joint. Since this involves working at heights, technicians usually need to set up numerous scaffolding and other support structures to provide a platform for their work. The construction and relocation of these platforms are time-consuming and labor-intensive, resulting in high labor costs. Furthermore, the arc light and fumes generated during welding can cause occupational hazards. Therefore, welding robots are generally used for automated welding. However, existing welding robots have poor adaptability to complex weld trajectories and lack real-time dynamic adjustment capabilities, leading to weld dimensions that do not meet requirements. This results in welding defects such as undercut, weld beads, arc craters, porosity, cracks, slag inclusions, incomplete penetration, and lack of fusion. These defects can reduce the load-bearing capacity by decreasing the weld cross-sectional area or cause stress concentration, leading to cracks and reduced fatigue strength of the structural steel, ultimately resulting in brittle fracture. Summary of the Invention

[0004] The purpose of this invention is to overcome the defects and problems of poor welding quality in the prior art, and to provide a continuous climbing automatic welding robot for structural steel with better welding quality and its welding method.

[0005] To achieve the above objectives, the technical solution of the present invention is: a continuous climbing automatic welding robot for structural steel, comprising: a continuous climbing mechanism, a synchronous lifter, a welding disc, a monitoring and identification system, a control system, and multiple rotary drive mechanisms. The continuous climbing mechanism is movably mounted on the outside of the structural steel, the synchronous lifter is mounted on the upper side of the continuous climbing mechanism, the multiple rotary drive mechanisms are respectively movably connected to the synchronous lifter through a horizontal displacement mechanism, the welding disc is mounted on the synchronous lifter, the output end of the rotary drive mechanism is connected to a robotic arm, the output end of the robotic arm is connected to a robotic hand, the robotic hand holds a welding torch, and the control system is connected to the continuous climbing mechanism, the rotary drive mechanism, the synchronous lifter, the horizontal displacement mechanism, the welding torch, the robotic arm, the robotic hand, and the monitoring and identification system.

[0006] The continuous climbing mechanism is used for continuous lifting and lowering on the structural steel.

[0007] The rotary drive mechanism is used to control the rotation of the robotic arm;

[0008] The synchronous lifter is used to drive the horizontal displacement mechanism to perform vertical lifting;

[0009] The horizontal displacement mechanism is used to drive the rotary drive mechanism to move horizontally;

[0010] The welding tray is used to store welding wire;

[0011] The welding torch is used to feed the welding wire, melt the welding wire to form a molten pool, and then fill the weld seam on the steel section to complete the welding.

[0012] The robotic arm is used to adjust the angle and position of the welding torch so that it is aligned with the weld seam of the steel section.

[0013] The robotic arm is used to hold the welding torch;

[0014] The monitoring and identification system is used to acquire the tilt angle and displacement distance of the welding torch, identify the surface features of the steel section and the contour features of the weld, and collect the molten pool temperature, deformation data and robotic arm vibration error during welding.

[0015] The control system is used to control the monitoring and identification system to scan the surface of the steel section and generate the initial welding trajectory of the welding torch according to the weld position, establish an independent spatial coordinate system and generate the welding path of the welding torch; according to the welding path, it controls the continuous climbing mechanism, rotary drive mechanism, synchronous lifter, horizontal displacement mechanism, robotic arm and robotic hand to work together, so that the welding torch moves at a constant speed along the planned welding path when moving horizontally, vertically and obliquely, while the inclination angle and distance between its head and the weld remains unchanged; it corrects the path deviation of the welding torch according to the vibration error and deformation data of the robotic arm; it dynamically adjusts the traveling speed, attitude, current and welding parameters of the welding torch according to the molten pool temperature and weld width deviation; and it performs quality assessment based on the weld droplet profile on the surface of the steel section.

[0016] The continuous climbing mechanism includes a frame, a first roller, a second roller, a synchronous chain, a first sprocket, a second sprocket, a drive sprocket, and a drive motor. The frame is arranged on the outside of the structural steel. The first roller and the second roller are respectively rotatably connected to the frame and respectively fit against the front and rear sides of the structural steel. The first sprocket and the second sprocket are respectively connected to one end of the first roller and the second roller. The drive motor is mounted on the frame. The drive sprocket is connected to the output end of the drive motor. The drive sprocket and the second sprocket are respectively meshed with the inside of the synchronous chain. The first sprocket is meshed with the outside of the synchronous chain. A seat is connected to one side of the frame.

[0017] The frame includes a limiting plate and two parallel first mounting plates and a second mounting plate. The first mounting plate and the second mounting plate are connected to each other by two horizontal plates. The two ends of the first roller and the second roller are rotatably connected to the limiting plate and the second mounting plate, respectively. The two ends of the limiting plate are respectively sleeved on the first roller and the second roller. Two limiting nuts abut against the outer side of the limiting plate. The two limiting nuts are respectively threaded to the other end of the first roller and the second roller. The limiting plate, the first roller, the second roller, and the second mounting plate together form a slot for accommodating the steel profile. Two positioning holes are opened on the limiting plate. The first mounting plate is connected and fixed to the two positioning holes on the limiting plate by two positioning pins.

[0018] The rotary drive mechanism includes a rotary motor, a vertical gear, and a gear disk. The rotary motor is mounted on the horizontal displacement mechanism, the vertical gear is mounted on the output end of the rotary motor, the gear disk is rotatably connected to the horizontal displacement mechanism and meshes with the vertical gear, and the bottom of the robotic arm is connected to the gear disk.

[0019] The synchronous lifter includes four bases and a servo motor. The four bases are respectively connected to the upper side of the frame and arranged in an array. A column is vertically connected to the upper side of each base. A double-sided rack is connected to the adjacent two sides of the column. A displacement seat is fitted on the outer circumference of the column. A cavity is opened in the displacement seat. A gear shaft is rotatably connected between two adjacent displacement seats. The two ends of the gear shaft pass through the two adjacent displacement seats and are located in the two cavities. A spur gear and a bevel gear are connected to both ends of the gear shaft. The two spur gears are respectively meshed with one side of the two adjacent double-sided racks. The bevel gears on the two adjacent gear shafts are meshed with each other. The servo motor is mounted on one of the displacement seats and its output shaft passes through the displacement seat and is coaxially connected to the end of one of the gear shafts. The servo motor is connected to the control system.

[0020] The horizontal displacement mechanism includes a guide rail, a linear reciprocating motor, a sliding plate, and a slide rail. The guide rail and slide rail are both connected between two displacement seats along the long side. The linear reciprocating motor is slidably connected to the outer periphery of the guide rail. One side of the sliding plate is connected to the linear reciprocating motor, and the other side of the sliding plate is slidably connected to the outer side of the slide rail. The linear reciprocating motor is connected to the control system.

[0021] The robotic arm includes a first link, a second link, a first connecting plate, a second connecting plate, a first electric push rod, a third link, a fourth link, a third connecting plate, a second electric push rod, and a connecting spring. The first connecting plate is connected to the upper side of the gear plate. One end of the first link and the second link are respectively hinged to the first connecting plate, and the other end of the first link and the second link are respectively hinged to the second connecting plate. The movable end of the first electric push rod is hinged to the second link, and the fixed end of the first electric push rod is hinged to the first link. One end of the third and fourth links is hinged to the second connecting plate, and the other end of the third and fourth links is hinged to the third connecting plate. One end of the connecting spring is connected to the third link, and the other end of the connecting spring is connected to the fourth link. The fixed end of the second electric push rod is hinged to the first link, and the movable end of the second electric push rod is hinged to the fourth link. The bottom end of the mounting base of the robot arm is hinged to the third connecting plate, and the top end of the mounting base is hinged to the upper part of the third link through the third electric push rod.

[0022] The robotic arm includes a mounting base, a servo cylinder, a mounting frame, multiple support rods, and multiple connecting rods. One side of the mounting base is connected to the end of the robotic arm. The servo cylinder is mounted on the other side of the mounting base. The piston rod of the servo cylinder passes through the mounting frame and is rotatably connected to a mounting block. A stop block is mounted on the outer circumferential surface of the piston rod of the servo cylinder. The mounting frame is located outside the piston rod. The inner side of the mounting frame has a spiral groove matching the stop block along the axial direction of the piston rod. The stop block is slidably connected to the spiral groove. Multiple support rods are evenly arranged circumferentially on the mounting frame. One end of each support rod is hinged to the mounting frame, and the other end of each support rod is connected to a replaceable gripper. Multiple replaceable grippers abut against the outside of the welding torch. Multiple connecting rods correspond one-to-one with multiple support rods. One end of each connecting rod is circumferentially hinged to the mounting block, and the other end of each connecting rod is hinged to the support rod.

[0023] The welding torch includes a torch body, two clamping blocks, and a conductive nozzle. A gas and wire feeding channel penetrating the outer shell is formed along the length of the torch body. The conductive nozzle is located at the front of the torch body. The two clamping blocks are symmetrically arranged at the rear of the torch body. One clamping block is connected to the inner wall of the torch body via a spring. Each clamping block has three rollers rotatably connected to it. Rollers are connected to the outer circumference of each roller, and a gap is provided between adjacent rollers for the welding wire to pass through. The three rollers on the other clamping block pass through the torch body and are sequentially fitted with a driving gear, an idler gear, and a driven gear. The driving gear and driven gear rotate synchronously with the rollers. The idler gear meshes with the driving gear, and the driven gear rotates synchronously with the driving gear via the idler gear.

[0024] A welding method for a continuous climbing automatic welding robot for structural steel, the welding method comprising the following steps:

[0025] Step 1: Install the continuous climbing mechanism on the outside of the steel profile, then install the synchronous lifter on the continuous climbing mechanism, and then install the horizontal displacement mechanism, rotary drive mechanism, robotic arm, robotic hand, welding torch, monitoring and identification system and control system in sequence.

[0026] Step 2: Pre-set the welding process library and establish a rectangular coordinate system for welding space. Use the monitoring and recognition system to perform a comprehensive scan of the steel surface and perform 3D modeling to identify the weld seam and generate the initial welding trajectory. The industrial control computer in the control system controls the equipment to simulate the pre-action, and controls the continuous climbing mechanism to continuously climb on the steel. The continuous climbing mechanism, rotary drive mechanism, synchronous lifter, horizontal displacement mechanism, robotic arm, and robotic hand work together to make the welding torch head move along the initial welding trajectory. During the movement, the monitoring and recognition system automatically determines whether the welding torch is moving along the center of the weld seam. At the same time, the industrial control computer in the control system calculates the 3D coordinates of the welding torch head based on the data collected by the monitoring and recognition system to verify whether the welding path is correct. The welding torch moves at a constant speed along the predetermined welding path and maintains a preset relative distance from the weld seam through the dual control of the image and 3D coordinates identified by the monitoring and recognition system.

[0027] Step 3: The control system controls the continuous climbing mechanism to fall back to the starting position. According to the welding path, it controls each mechanism to carry out assembly line operation, so that the welding torch moves at a constant speed along the planned welding path when moving horizontally, vertically, and diagonally, and performs uniform welding on the steel weld. During the welding process, the monitoring and identification system collects temperature, robotic arm vibration error, and deformation data in real time and feeds them back to the control system. The control system dynamically corrects the path deviation of the robotic arm based on the data, and dynamically adjusts the traveling speed, posture, current magnitude, and welding parameters of the welding torch according to the molten pool temperature and weld width deviation.

[0028] Step 4: Upon completion of welding, the weld droplet profile on the steel surface is identified by the monitoring and identification system. The control system evaluates the welding quality based on the weld profile image features and promptly addresses and repairs welding defects.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0030] 1. In this invention, a continuous climbing automatic welding robot for structural steel and its welding method, the continuous climbing mechanism enables the welding robot to automatically and continuously climb, replacing manual labor for high-altitude operations with low labor intensity. Multiple welding torches allow for simultaneous welding on multiple sides, further improving efficiency and ensuring structural safety through rapid welding. Combined with a horizontal displacement mechanism, the welding torches can achieve maximum welding coverage within a predetermined area, adapting to complex working conditions. The robotic arm controls the angle and position of the welding torches, enabling uniform and continuous welding of horizontal, vertical, and oblique welds on the structural steel. It possesses excellent mobility. During the welding process, the combined operation of various mechanisms maintains the welding torch and structural steel weld. The relative distance between the surfaces remains constant, ensuring that the welding material evenly fills the entire weld seam, guaranteeing weld fullness and guaranteeing weld strength, sealing performance, and aesthetic appearance. Simultaneously, the monitoring and identification system can comprehensively scan the steel surface and perform 3D modeling to identify the weld seam and generate welding paths. Alternatively, it can use drag-and-drop teaching, online teaching programming, or offline programming to generate welding paths. For more complex weld seams, manual control mode can be switched for welding. The monitoring and identification system can also collect data on molten pool temperature, robotic arm vibration, weld width deviation, and deformation during welding. This allows for dynamic adjustment of the welding torch posture, travel speed, current magnitude, and welding parameters, effectively ensuring welding quality through process control. Therefore, this invention offers high welding efficiency and good welding quality.

[0031] 2. This invention discloses a continuous climbing automatic welding robot for structural steel and its welding method. It utilizes two rollers in line contact with the surface of the structural steel, and employs a seat and counterweights to shift the center of gravity outwards. Based on the lever principle, the inward pressure exerted by the rollers on both sides of the structural steel is amplified to prevent slippage. Manual, remote, or wired operation can rotate the drive motor, which in turn rotates the synchronous chain. This causes the first and second sprockets to rotate synchronously in opposite directions, providing a pair of vertical lifting forces. This allows the device to automatically rise or fall as a whole, replacing manual labor for high-altitude operations without the need for additional work platforms or equipment. Therefore, this invention offers low workload and high safety.

[0032] 3. In the present invention, a continuous climbing automatic welding robot for structural steel and its welding method, a limiting plate is provided to facilitate the direct insertion of the frame into the structural steel from the side. A limiting nut is used to limit the limiting plate and prevent structural loosening. A tensioning sprocket is provided to adjust the tension of the synchronous chain, thereby making the synchronous chain rotation process more stable. A worm gear transmission is used, utilizing its unidirectional power transmission and self-locking function to ensure stable stopping and automatic braking when the drive motor has no power output, preventing the rollers from reversing and causing the equipment to slip. Therefore, the present invention has high safety and good stability.

[0033] 4. In the present invention, a continuous climbing automatic welding robot for structural steel and its welding method, the overall lifting height is ensured by controlling the rotation angle of the servo motor. The synchronous lifter is formed by the meshing of spur gears and double-sided racks on each gear shaft. Simultaneously, bevel gears at the ends of adjacent gear shafts mesh with each other to transmit torque. Under the output torque of the servo motor, the spur gears and bevel gears achieve double meshing linkage and rotate in the same direction, causing the four displacement seats to rise and fall synchronously along the double-sided rack. This drives the displacement mechanism on the displacement seats to follow the overall lifting and falling on the stable displacement seats. This double meshing and co-directional rotation effectively prevents asynchronous lifting and falling due to mechanical failure of the synchronous lifter. By adding a slide rail below the linear reciprocating motor, combined with a sliding plate, the robot arm can slide horizontally, effectively bearing the weight of the robot arm and preventing deformation of the linear reciprocating motor guide rail. Therefore, the present invention has a stable working process and high reliability.

[0034] 5. In the present invention, a continuous climbing automatic welding robot for structural steel and its welding method, a rotating motor drives a gear to rotate, which in turn drives a gear plate and a robotic arm to rotate, enabling the robotic arm to rotate 360 ​​degrees vertically. The robotic arm adopts a spatial parallel four-bar linkage, which facilitates free deformation of the robotic arm. Utilizing the instability of parallelograms and the stability of triangles, an electric push rod and diagonal brace form the hypotenuse, dividing the parallelogram into two variable trapezoids with significantly different upper and lower base lengths. The entire trapezoid gradually approaches a triangle, thus achieving stability. This allows the robotic arm to work at any position within a 360-degree space with the maximum extension length of the robotic arm as its radius. Therefore, the present invention features a lightweight structure, good flexibility, and good stability.

[0035] 6. In the present invention, a continuous climbing automatic welding robot for structural steel and its welding method, the robotic arm employs multiple replaceable grippers. Besides gripping the welding torch, it can also hold a rust removal device to remove rust from the welding surface before welding. The robotic arm is driven by a servo electric cylinder, which moves the connecting rod. Since the connecting rod is hinged to the support rod, it causes the support rod to rotate on the mounting frame, thereby allowing the multiple grippers to grip or release the welding torch. During the movement of the servo electric cylinder, a stop block moves within a spiral groove, causing the mounting frame to rotate circumferentially. This facilitates adjustment of the gripper's position and angle. Combined with the gripper's own clamping force, it achieves adaptive fitting to the welding torch size and efficient gripping of the welding torch. Therefore, the present invention offers a stable gripping process and a wide range of applications.

[0036] 7. In the present invention, a continuous climbing automatic welding robot for structural steel and its welding method, the clamping block is connected to the gun body by a spring. Friction braking not only clamps the welding wire but also automatically adapts to the diameter of the welding material for continuous feeding. The rollers use gear transmission for easy control of the feeding speed. Three pairs of rollers, while feeding, can straighten the welding material, ensuring the electrode head is stably held in the center of the weld. The rollers are driven by a drive gear and a driven gear, ensuring synchronous feeding of the welding wire within the welding gun. Therefore, the present invention has wide applicability and a stable welding process. Attached Figure Description

[0037] Figure 1 This is a structural schematic diagram of an automatic welding robot for continuous climbing of steel profiles according to the present invention.

[0038] Figure 2 This is a schematic diagram of the continuous climbing mechanism and the steel profile in this invention.

[0039] Figure 3 This is a schematic diagram of the continuous climbing mechanism in this invention.

[0040] Figure 4 This is a schematic diagram of the frame structure in this invention.

[0041] Figure 5 This is a partial cross-sectional view of the limiting plate, the first mounting plate, and the second mounting plate in this invention.

[0042] Figure 6 This is a schematic diagram of the tensioning sprocket, adjusting column, and adjusting block in this invention.

[0043] Figure 7 This is a schematic diagram of the structure of the synchronization chain, the first sprocket, the second sprocket, and the drive sprocket in this invention.

[0044] Figure 8 This is a schematic diagram of the synchronous lift, robotic arm, robotic hand, welding torch, and displacement mechanism in this invention.

[0045] Figure 9 This is a partial structural schematic diagram of the synchronous lifting device in this invention.

[0046] Figure 10 This is a partial cross-sectional schematic diagram of the column, displacement seat, gear shaft, gear, and double-sided rack in this invention.

[0047] Figure 11 This is a schematic diagram of the drive mechanism and displacement mechanism in this invention.

[0048] Figure 12 This is a schematic diagram of the structure of the robotic arm and robotic hand in this invention.

[0049] Figure 13 This is a schematic diagram of the robotic arm in this invention.

[0050] Figure 14 This is a schematic diagram of the mounting block and servo electric cylinder in this invention.

[0051] Figure 15 This is a schematic diagram of the mounting frame and support rod in this invention.

[0052] Figure 16 This is a schematic diagram of the welding torch in this invention.

[0053] Figure 17 This is a cross-sectional schematic diagram of the welding torch in this invention.

[0054] Figure 18 This is a connection block diagram of the control system and the monitoring and identification system in this invention.

[0055] In the diagram: 1. Steel section; 2. Continuous climbing mechanism; 21. Frame; 22. First mounting plate; 23. Second mounting plate; 24. Horizontal plate; 25. Slot; 26. Slide groove; 27. Counterweight; 28. Positioning hole; 29. ​​Positioning pin; 210. First roller; 211. Second roller; 212. Synchronous chain; 213. First sprocket; 214. Second sprocket; 215. Drive sprocket; 216. Drive motor; 217. Tensioning sprocket; 218. Adjusting column; 219. Adjusting block; 220. Tensioning bolt; 221. Limiting plate; 222. First anti-slip roller; 223. Second anti-slip roller; 24. Column. 224 Roller bearing, 225 Worm gearbox, 226 Seat, 227 Wheel rim, 228 Limit nut, 3 Rotary drive mechanism, 31 Rotary motor, 32 Vertical gear, 33 Gear plate, 4 Synchronous lifter, 41 Base, 42 Column, 43 Double-sided rack, 44 Displacement seat, 45 Cavity, 46 Gear shaft, 47 Spur gear, 48 Servo motor, 49 Bevel gear, 410 Anti-arc plate, 5 Horizontal displacement mechanism, 51 Linear reciprocating motor, 52 Guide rail, 53 Slide plate, 54 Slide rail, 6 Welding disc, 7 Welding torch, 71 Torch body, 72 Clamping block 73. Spring, 74. Air and wire feeding channel, 75. Conductive nozzle, 76. Roller, 77. Drive gear, 78. Idler gear, 79. Driven gear, 710. Robotic arm, 81. First link, 82. Second link, 83. First connecting plate, 84. Second connecting plate, 85. First electric push rod, 86. Third link, 87. Fourth link, 88. Third connecting plate, 89. Second electric push rod, 810. Connecting tension spring, 811. Third electric push rod, 91. Robotic arm, 91. Mounting base, 92. Servo cylinder, 921. Piston rod, 93. Support rod, 94. Mounting block, 95. Connecting block. 41. Connecting plate 942. Trapezoidal slide 943. Elastic element 944. Mounting bracket 95. Spiral groove 951. Sleeve 952. Mounting plate 953. Inclined surface 954. Connecting rod 96. Connecting rod 961. Replaceable gripper 97. Stop block 98. Monitoring and identification system 10. Laser scanner 101. Infrared temperature sensor 102. Ultrasonic wind speed and direction sensor 103. Inertial measurement unit 104. LiDAR 105. Imaging spectrometer 106. Control system 11. Industrial computer 111. Wired control system 112. Visual remote control system 113. Detailed Implementation

[0056] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0057] Example 1:

[0058] See Figures 1 to 18An automatic welding robot for continuous climbing of structural steel includes: a continuous climbing mechanism 2, a synchronous lifter 4, a welding disc 6, a monitoring and identification system 10, a control system 11, and multiple rotary drive mechanisms 3. The continuous climbing mechanism 2 is movably installed on the outside of the structural steel 1. The synchronous lifter 4 is installed on the upper side of the continuous climbing mechanism 2. The multiple rotary drive mechanisms 3 are movably connected to the synchronous lifter 4 through horizontal displacement mechanisms 5. The welding disc 6 is installed on the synchronous lifter 4. The output end of the rotary drive mechanism 3 is connected to a robotic arm 8. The output end of the robotic arm 8 is connected to a robotic hand 9. The robotic hand 9 holds a welding torch 7. The control system 11 is connected to the continuous climbing mechanism 2, the rotary drive mechanism 3, the synchronous lifter 4, the horizontal displacement mechanism 5, the welding torch 7, the robotic arm 8, the robotic hand 9, and the monitoring and identification system 10.

[0059] The continuous climbing mechanism 2 is used for continuous lifting and lowering on the steel section 1;

[0060] The rotary drive mechanism 3 is used to control the rotation of the robotic arm 8;

[0061] The synchronous lifting device 4 is used to drive the horizontal displacement mechanism 5 to perform vertical lifting;

[0062] The horizontal displacement mechanism 5 is used to drive the rotary drive mechanism 3 to move horizontally;

[0063] The welding tray 6 is used to store welding wire;

[0064] The welding torch 7 is used to feed the welding wire, melt the welding wire to form a molten pool, and then fill the weld seam on the steel section 1 to complete the welding.

[0065] The robotic arm 8 is used to adjust the angle and position of the welding torch 7 so that it is aligned with the weld seam of the steel section 1;

[0066] The robotic arm 9 is used to hold the welding torch 7;

[0067] The monitoring and identification system 10 is used to acquire the tilt angle and displacement distance of the welding torch 7, identify the surface features and weld contour features of the steel section 1, and collect the molten pool temperature, deformation data and robotic arm vibration error during welding.

[0068] The control system 11 is used to control the monitoring and identification system 10 to scan the surface of the steel section 1 and generate the initial welding trajectory of the welding torch 7 according to the weld position, establish an independent spatial coordinate system and generate the welding path of the welding torch 7; according to the welding path, control the continuous climbing mechanism 2, the rotary drive mechanism 3, the synchronous lifter 4, the horizontal displacement mechanism 5, the robotic arm 8, and the robotic hand 9 to work together, so that the welding torch 7 moves at a constant speed according to the planned welding path when moving horizontally, vertically, and obliquely, while the inclination angle and distance between its head and the weld remains unchanged; correct the path deviation of the welding torch 7 according to the vibration error and deformation data of the robotic arm; dynamically adjust the traveling speed, attitude, current magnitude and welding parameters of the welding torch 7 according to the molten pool temperature and weld width deviation; and perform quality assessment according to the weld droplet profile on the surface of the steel section 1.

[0069] In this embodiment, the surface features of the steel section 1 are the surface images of the steel section 1, including the weld position between two steel sections 1. The deformation data refers to the deformation of the weld, including the transverse and longitudinal shrinkage and deformation of the weld. The weld contour features refer to the shape and size deviation of the weld. The size deviation includes the weld reinforcement height, width and other deviations. The welding torch 7 uses electric arc discharge to convert electrical energy into heat energy. Before welding, the continuous climbing mechanism 2 is first fitted into the steel section 1. The control system 11 controls the continuous climbing mechanism 2 to continuously climb on the steel section 1. During welding, the synchronous lifting device 4 can realize the synchronous lifting of multiple welding torches 7. At the same time, the robotic arm 8 moves horizontally on the synchronous lifting device 4 through the horizontal displacement mechanism 5. The rotation drive mechanism 3 drives the robotic arm 8 to perform a 360-degree vertical circular motion. The robotic hand 9 can clamp and change the tilt angle of the welding torches 7. The angle and position of the welding torches 7 are controlled by the combination of the synchronous lifting device 4, the horizontal displacement mechanism 5, the robotic arm 8, and the robotic hand 9, so as to realize continuous and uniform welding of the horizontal, vertical, and oblique welds of the steel section 1. During the movement, the joint work of each mechanism makes the welding material delivered by the welding torch 7 evenly fill the entire weld to complete the welding.

[0070] The monitoring and identification system 10 includes a laser scanner 101, an infrared temperature sensor 102, an ultrasonic wind speed and direction sensor 103, an inertial measurement unit 104, a lidar 105, and an imaging spectrometer 106. The lidar 105 is installed on the upper side of the robotic arm 8 and the lower side of the continuous climbing mechanism 2, respectively, to measure the distance between the robot and obstacles and to monitor the surrounding safety environment during the robot's climbing process. The laser scanner 101, infrared temperature sensor 102, ultrasonic wind speed and direction sensor 103, and inertial measurement unit 104 are installed on the robotic arm 8 and the robotic hand 9. Before welding, the laser scanner 101 performs a comprehensive scan of the area to be welded to create a three-dimensional model. In the rectangular coordinate system of the welding space, the three-dimensional coordinates are extracted based on the weld features to generate the working path of the welding mechanism. The imaging spectrometer 106 is used to scan the weld surface during the welding process and compare the acquired spectral features with the preset simulated spectrum. Feature comparison is used to determine the welding quality based on image features. Infrared temperature sensor 102 is used to monitor the molten pool temperature and dynamically adjust the current, voltage, and wire feeding speed of welding torch 7 according to the molten pool state. Ultrasonic wind speed and direction sensor 103 is used to measure the wind direction and speed during welding, so as to facilitate dynamic correction of welding trajectory and movement speed according to wind speed and direction. Inertial measurement unit 104 is used to acquire the real-time three-dimensional coordinates of the welding torch 7 head and the shaking of robotic arm 8. Control system 11 includes industrial computer 111, wired control system 112 and visual remote control system 113. Industrial computer 111 controls the assembly line operation of each mechanism according to operation instructions and workflow. Each sensor feeds back the measured data to industrial computer 111 in real time. Under interference-free conditions, the visual remote control system 113 can be used to send work instructions to industrial computer 111. When there is interference, the wired control system 112 is used to send work instructions to industrial computer 111.

[0071] Example 2:

[0072] The basic content is the same as in Example 1, except that:

[0073] See Figures 2 to 7The continuous climbing mechanism 2 includes a frame 21, a first roller 210, a second roller 211, a synchronous chain 212, a first sprocket 213, a second sprocket 214, a drive sprocket 215, and a drive motor 216. The frame 21 is arranged on the outside of the profile 1. The first roller 210 and the second roller 211 are respectively rotatably connected to the frame 21 and respectively attached to the front and rear sides of the profile 1. The first sprocket 213 and the second sprocket 214 are respectively connected to one end of the first roller 210 and the second roller 211. The drive motor 216 is mounted on the frame 21. The drive sprocket 215 is connected to the output end of the drive motor 216. The drive sprocket 215 and the second sprocket 214 are respectively meshed with the inside of the synchronous chain 212. The first sprocket 213 is meshed with the outside of the synchronous chain 212. A seat 226 is connected to one side of the frame 21.

[0074] In this embodiment, considering the large load and low-speed transmission of the sprocket, a double-row synchronous chain structure is adopted. The drive sprocket 215, the first sprocket 213, and the second sprocket 214 are all double-row sprockets, and the synchronous chain 212 is a double-row chain. When working on the horizontal or inclined steel section 1, the first roller 210 should be placed on the upper part of the steel section 1, and the second roller 211 should be placed on the lower part of the steel section 1. If there is not enough space in the upper part to place the counterweight, the counterweight can be suspended on the lower part of the steel section 1 through the hanging rod to apply friction to the steel section 1 to facilitate movement.

[0075] In use, a person can sit on seat 226 to monitor the equipment. The drive motor 216 rotates forward, driving the drive sprocket 215 to rotate. The drive sprocket 215 drives the synchronous chain 212 to rotate. Since the first sprocket 213 is located on the outside of the synchronous chain 212 and the second sprocket 214 is located on the inside of the synchronous chain 212, after the synchronous chain 212 rotates, the first sprocket 213 and the second sprocket 214 will rotate in opposite directions, applying a pair of torques to the steel profile 1, so that the equipment can be raised as a whole.

[0076] Example 3:

[0077] The basic content is the same as in Example 1, except that:

[0078] See Figures 3 to 7The frame 21 includes a limiting plate 221 and two parallel first mounting plates 22 and second mounting plates 23. The first mounting plates 22 and second mounting plates 23 are connected to each other by two horizontal plates 24. The two ends of the first roller 210 and the second roller 211 are rotatably connected to the limiting plate 221 and the second mounting plate 23, respectively. The two ends of the limiting plate 221 are respectively sleeved on the first roller 210 and the second roller 211. The outer side of the limiting plate 221 abuts against two limiting nuts 228. The two limiting nuts 228 are respectively threaded to the other end of the first roller 210 and the second roller 211. The limiting plate 221, the first roller 210, the second roller 211, and the second mounting plate 23 together form a slot 25 for accommodating the steel section 1. The limiting plate 221 has two positioning holes 28. The first mounting plate 22 is connected and fixed to the two positioning holes 28 on the limiting plate 221 by two positioning pins 29, respectively.

[0079] In this embodiment, the counterweight 27 is connected between the first mounting plate 22 and the second mounting plate 23. The output end of the drive motor 216 is connected to the worm gearbox 225, the drive sprocket 215 is connected to the output end of the worm gearbox 225, the inner side of the synchronous chain 212 is meshed with the tension sprocket 217, one end of the tension sprocket 217 is connected to the adjusting column 218, a groove 26 is provided on one side of the second mounting plate 23, the adjusting column 218 is slidably connected to the groove 26, one end of the adjusting column 218 is threadedly connected to the tension bolt 220, the outer circumferential surface of the tension bolt 220 is threadedly connected to the adjusting block 219, and the adjusting block 219 is connected to the second mounting plate. 23. A first anti-slip roller 222 is connected to the outer peripheral surface of the first roller 210. The first anti-slip roller 222 has rims 227 at both ends. The first anti-slip roller 222 is tactilely connected to the outer side of the profile steel 1. The two ends of the first roller 210 are connected to the first mounting plate 22 and the second mounting plate 23 respectively through cylindrical roller bearings 224. A second anti-slip roller 223 is connected to the outer peripheral surface of the second roller 211. The second anti-slip roller 223 has rims 227 at both ends. The second anti-slip roller 223 is tactilely connected to the outer side of the climbing carrier. The two ends of the second roller 211 are connected to the limiting plate 221 and the second mounting plate 23 respectively through cylindrical roller bearings 224.

[0080] The first anti-slip roller 222 and the second anti-slip roller 223 are made of rubber-coated anti-slip and wear-resistant material with raised dots. During climbing, the raised dots on the first anti-slip roller 222 and the second anti-slip roller 223 deform and squeeze the steel beam. Through friction, the first anti-slip roller 222 and the second anti-slip roller 223 move on the steel beam, thereby achieving stable climbing and descending of the equipment. When the drive motor 216 stops working, the first roller 210 and the second roller 211 have a tendency to reverse due to gravity. However, due to the worm gearbox 225, the drive sprocket 215 cannot reverse, so the first roller 210 and the second roller 211 will not rotate in reverse, and the entire equipment will not slip.

[0081] Before use, first unscrew the two limit nuts 228, remove the limit plate 221, then directly insert the frame 21 from the side of the steel section 1, and then put the limit plate 221 onto the first roller 210 and the second roller 211, and screw in the limit nuts 228 to complete the connection and fixation. By adding the counterweight 27, the friction force is amplified through the lever principle to resist the downward force, making the upward process of the frame 21 safer.

[0082] Example 4:

[0083] The basic content is the same as in Example 1, except that:

[0084] See Figures 8 to 10 The synchronous lifting device 4 includes four bases 41 and a servo motor 48. The four bases 41 are respectively connected to the upper side of the frame 21 and arranged in an array. A column 42 is vertically connected to the upper side of each base 41. A double-sided rack 43 is connected to the adjacent two sides of the column 42. A displacement seat 44 is fitted on the outer circumference of the column 42. A cavity 45 is opened in the displacement seat 44. A gear shaft 46 is rotatably connected between two adjacent displacement seats 44. The two ends of the gear shaft 46 pass through the two adjacent displacement seats respectively. The gear shaft 46 is located in one of the two cavities 45. Both ends of the gear shaft 46 are connected to a spur gear 47 and a bevel gear 49. The two spur gears 47 are respectively meshed with one side of the two adjacent double-sided racks 43. The bevel gears 49 on the two adjacent gear shafts 46 are meshed with each other. The servo motor 48 is mounted on one of the displacement seats 44 and its output shaft passes through the displacement seat 44 and is coaxially connected to the end of one of the gear shafts 46. The servo motor 48 is connected to the control system 11.

[0085] In this embodiment, there are four bases 41, and the four columns 42 are distributed parallel to each other outside the four apex corners of the steel 1. An anti-arc light plate 410 can be set on the outside of the column 42. The height of the anti-arc light plate 410 is greater than the height of the column 42. The four anti-arc light plates 410 can construct a temporarily sealed space to prevent wind and arc light leakage. The column 42 has a square cross section. A double-sided rack 43 is obtained by machining racks on the adjacent two sides of the column 42. The double-sided rack 43 has a rectangular cross section. The control system 11 controls the servo motor 48 to work. The overall lifting height is guaranteed by changing the rotation angle of the servo motor 48. The spur gear 47 and the double-sided rack 43 are meshed and installed in the displacement seat 44. At the same time, the surface of the double-sided rack 43 is treated with titanium nitride coating to reduce the gear transmission resistance during linkage lifting.

[0086] Example 5:

[0087] The basic content is the same as in Example 1, except that:

[0088] See Figure 11 The rotary drive mechanism 3 includes a rotary motor 31, a vertical gear 32, and a gear disk 33. The rotary motor 31 is mounted on the horizontal displacement mechanism 5. The vertical gear 32 is mounted on the output end of the rotary motor 31. The gear disk 33 is rotatably connected to the horizontal displacement mechanism 5 and meshes with the vertical gear 32. The bottom of the robotic arm 8 is connected to the gear disk 33. The horizontal displacement mechanism 5 includes a guide rail 52, a linear reciprocating motor 51, a sliding plate 53, and a slide rail 54. The guide rail 52 and the slide rail 54 are both connected between two displacement seats 44 along the long side. The linear reciprocating motor 51 is slidably connected to the outer periphery of the guide rail 52. One side of the sliding plate 53 is connected to the linear reciprocating motor 51, and the other side of the sliding plate 53 is slidably connected to the outer side of the slide rail 54. The linear reciprocating motor 51 is connected to the control system 11.

[0089] In this embodiment, the synchronous lifter 4 is connected as one unit by the guide rail 52 and the linear reciprocating motor 51. The rotating motor 31 drives the vertical gear 32 to rotate, thereby driving the gear plate 33 to rotate synchronously. Since the robotic arm 8 is connected to the gear plate 33, it will drive the robotic arm 8 to rotate 360 ​​degrees vertically. The linear reciprocating motor 51 can move back and forth between the two displacement seats 44, thereby driving the robotic arm 8 to move horizontally. The back of the slide plate 53 is hook-shaped and is locked on the slide rail 54. When the linear reciprocating motor 51 moves, it will synchronously drive the slide plate 53 to move on the slide rail 54.

[0090] Example 6:

[0091] The basic content is the same as in Example 1, except that:

[0092] See Figure 12 The robotic arm 8 includes a first link 81, a second link 82, a first connecting plate 83, a second connecting plate 84, a first electric push rod 85, a third link 86, a fourth link 87, a third connecting plate 88, a second electric push rod 89, and a connecting spring 810. The first connecting plate 83 is connected to the upper side of the gear disk 33. One end of the first link 81 and the second link 82 are respectively hinged to the first connecting plate 83, and the other end of the first link 81 and the second link 82 are respectively hinged to the second connecting plate 84. The movable end of the first electric push rod 85 is hinged to the second link 82, and the fixed end of the first electric push rod 85 is hinged to the first link 81. One end of the third link 86 and the fourth link 87 are respectively hinged to the second connecting plate 84, and the other end of the third link 86 and the fourth link 87 are respectively hinged to the third connecting plate 88. One end of the connecting spring 810 is connected to the third link 86, and the other end of the connecting spring 810 is connected to the fourth link 87. The fixed end of the second electric push rod 89 is hinged to the first link 81, and the movable end of the second electric push rod 89 is hinged to the fourth link 87. The bottom end of the mounting base 91 of the robot arm 9 is hinged to the third connecting plate 88, and the top end of the mounting base 91 is hinged to the upper part of the third link 86 through the third electric push rod 811.

[0093] In this embodiment, the first link 81 and the second link 82 are of equal length and parallel to each other, and the third link 86 and the fourth link 87 are of equal length and parallel to each other. During operation, the first electric push rod 85 drives the first link 81 and the second link 82 to rotate on the first connecting plate 83, and the second electric push rod 89 drives the fourth link 87 to rotate on the second connecting plate 84. Due to the connection spring 810, it can be positioned dynamically. Thus, the first electric push rod 85 and the second electric push rod 89 can make the robotic arm 8 deform freely. The third electric push rod 811 can make the robotic hand 9 rotate around the third connecting plate 88 of the robotic arm 8 to a certain extent, thereby enabling the robotic hand 9 to work at any position within a 360-degree space with the maximum extension length of the robotic arm 8 as the radius.

[0094] Example 7:

[0095] The basic content is the same as in Example 1, except that:

[0096] See Figures 13 to 15The robotic arm 9 includes a mounting base 91, a servo cylinder 92, a mounting frame 95, multiple support rods 93, and multiple connecting rods 96. One side of the mounting base 91 is connected to the end of the robotic arm 8. The servo cylinder 92 is mounted on the other side of the mounting base 91. The piston rod 921 of the servo cylinder 92 passes through the mounting frame 95 and is rotatably connected to a mounting block 94. A stop block 98 is mounted on the outer circumferential surface of the piston rod 921 of the servo cylinder 92. The mounting frame 95 is located outside the piston rod 921, and the inner side of the mounting frame 95 is provided with a section along the axial direction of the piston rod 921. A spiral groove 951 is matched with the stop block 98, and the stop block 98 is slidably connected to the spiral groove 951. A plurality of support rods 93 are evenly arranged on the mounting frame 95 in the circumferential direction. One end of the support rod 93 is hinged to the mounting frame 95, and the other end of the support rod 93 is connected to a replaceable claw 97. A plurality of replaceable claws 97 abut against the outside of the welding torch 7. A plurality of connecting rods 96 correspond one-to-one with a plurality of support rods 93. One end of a plurality of connecting rods 96 is respectively hinged to the mounting block 94 in the circumferential direction, and the other end of a plurality of connecting rods 96 is hinged to the support rod 93.

[0097] In this embodiment, there are three replaceable grippers 97. The inner sidewalls of the replaceable grippers 97 are provided with anti-slip textures. The three replaceable grippers 97 are circumferentially distributed around the axis of the piston rod 921, and the angle between each replaceable gripper 97 is 120 degrees. Therefore, it can reliably clamp various types of welding torches 7 or rust removal devices for operation. During clamping, the piston rod 921 of the servo cylinder 92 retracts, driving the mounting block 94 to move, which in turn causes the connecting rod 96 to rotate, driving the support rod 93 to move inward, so that the three replaceable grippers 97 clamp the welding torch 7. If the piston rod 921 continues to retract while clamping the welding torch 7, the stop block 98 will move into the spiral groove 951, driving the mounting frame 95 to rotate, so that the three replaceable grippers 97 drive the workpiece to rotate synchronously. If the stroke of the servo cylinder 921 is short, it can be used in the active position. A connecting rod is connected to the end of the piston rod 921. A bearing can be installed between the mounting frame 95 and the mounting base 91 to stabilize the rotation of the mounting frame 95. The mounting frame 95 includes a sleeve 952 and multiple mounting plates 953. The sleeve 952 is coaxially arranged on the outside of the piston rod 921. Multiple mounting plates 953 are connected to the outer circumferential surface of the sleeve 952 along the circumferential direction. One end of each support rod 93 is rotatably connected between two adjacent mounting plates 953. A spiral groove 951 is located on the inner sidewall of the sleeve 952. The mounting block 94 includes a connecting block 941 and multiple connecting plates 942. The connecting block 941 is cylindrical and rotatably connected to one end of the piston rod 921. Multiple connecting plates 942 are connected to one end of the connecting block 941 along the circumferential direction. One end of each connecting rod 96 is rotatably connected between two adjacent connecting plates 942.

[0098] Multiple connecting plates 942 are arranged in a one-to-one correspondence with multiple mounting plates 953. The mounting plate 953 has an inclined surface 954 on its lower side near the connecting plate 942. The connecting plate 942 is a right-angled triangle. The right-angled side of the connecting plate 942 is slidably connected to the connecting block 941 in the radial direction. The inclined side of the connecting plate 942 abuts against the inclined surface 954. The connecting rod 96 includes two symmetrically arranged connecting rods 961. One end of the two connecting rods 961 is rotatably connected to the left and right sides of the connecting plate 942. The other end of the two connecting rods 961 is rotatably connected to the left and right sides of the support rod 93. Multiple trapezoidal grooves 943 are radially opened on one end face of the connecting block 941. Elastic elements 944 are installed in the trapezoidal grooves 943. The shapes of the multiple connecting plates 942 and the multiple trapezoidal grooves 943 at the connection points correspond one-to-one and are slidably connected to the multiple trapezoidal grooves 943 respectively. One side of the elastic element 944 is connected to the connecting plate 942.

[0099] Multiple trapezoidal grooves 943 are welded to the outer circumference to prevent the connecting plate 942 from being pushed out. A bearing can be installed between the connecting block 941 and the piston rod 921. The elastic element 944 can be a spring. One end of the spring is connected to the inner wall of the trapezoidal groove 943, and the other end is connected to the other right-angle side of the connecting plate 942. During the clamping process, the piston rod 921 retracts the servo electric cylinder 92. At this time, the connecting plate 942 slides along the inclined surface 954 of the mounting plate 953. At the same time, the connecting plate 942 slides in the trapezoidal groove 943 of the connecting block 941, causing one end of the connecting rod 96 to move.

[0100] Example 8:

[0101] The basic content is the same as in Example 1, except that:

[0102] See Figure 17 and Figure 18 The welding torch 7 includes a torch body 71, two clamping blocks 72, and a conductive nozzle 75. The torch body 71 has a gas and wire feeding channel 74 extending through the outer shell along its length. The conductive nozzle 75 is located at the front of the torch body 71. The two clamping blocks 72 are symmetrically arranged at the rear of the torch body 71. One of the clamping blocks 72 is connected to the inner wall of the torch body 71 via a spring 73. Each clamping block 72 is rotatably connected to three rollers 76. The outer periphery of each roller 76... The surface is connected to rollers 77, and a gap is provided between two adjacent rollers 77 for the welding wire to pass through. Three rollers 76 on another clamping block 72 pass through the gun body 71 and are sequentially fitted with a drive gear 78, an idler gear 79, and a driven gear 710. The drive gear 78 and the driven gear 710 rotate synchronously with the rollers 77. The idler gear 79 is meshed with the drive gear 78, and the driven gear 710 rotates synchronously with the drive gear 78 through the idler gear 79.

[0103] In this embodiment, the conductive tip 75 can be a conductive tip known in the art. The welding wire is wound on the welding disc 6, and one end extends out and is connected to the gas and wire feeding channel 74 of the gun body 71. The gas and wire feeding channel 74 is connected to a gas supply device, which is used to supply protective gas. Then, the drive motor 711 works, driving the drive gear 78, idler gear 79, and driven gear 710 to rotate. Since the idler gear 79 is sleeved on the roller 76, it will not drive the roller 77 to rotate. The drive gear 78 and driven gear 710 rotate to drive the roller 77 to rotate synchronously for wire feeding. The current guided by the conductive tip 75 causes the welding wire to contact the steel section 1 to melt the arc and form molten droplets to fill the weld.

[0104] Example 9:

[0105] A welding method for a continuous climbing automatic welding robot for structural steel as described in Embodiment 1, the welding method comprising the following steps:

[0106] Step 1: Install the continuous climbing mechanism 2 on the outside of the steel section 1, then install the synchronous lifting device 4 on the continuous climbing mechanism 2, and install the horizontal displacement mechanism 5, the rotary drive mechanism 3, the robotic arm 8, the robotic hand 9, the welding torch 7, the monitoring and identification system 10, and the control system 11 in sequence.

[0107] Step 2: Pre-set the welding process library and establish a welding space rectangular coordinate system. Use the monitoring and recognition system 10 to perform a comprehensive scan of the surface of the steel section 1 and perform three-dimensional modeling to identify the weld and generate the initial welding trajectory. The industrial control computer 111 in the control system 11 controls the equipment to simulate the pre-action and controls the continuous climbing mechanism 2 to continuously climb on the steel section 1. Control the continuous climbing mechanism 2, the rotary drive mechanism 3, the synchronous lifter 4, the horizontal displacement mechanism 5, the robotic arm 8, and the robotic hand 9 to work together to make the head of the welding torch 7 move along the initial welding trajectory. During the movement, the monitoring and recognition system 10 automatically judges whether the welding torch 7 is moving along the center of the weld. At the same time, the industrial control computer 111 in the control system 11 calculates the three-dimensional coordinates of the head of the welding torch 7 based on the data collected by the monitoring and recognition system 10 to verify whether the welding path is correct. Through the dual control of the image and three-dimensional coordinates identified by the monitoring and recognition system 10, the welding torch 7 moves at a constant speed along the predetermined welding path and maintains a preset relative distance from the weld.

[0108] Step 3: The control system 11 controls the continuous climbing mechanism 2 to fall back to the starting position. According to the welding path, it controls each mechanism to carry out assembly line operation, so that the welding torch 7 moves at a constant speed along the planned welding path when moving horizontally, vertically, and diagonally, and performs uniform welding on the weld of the steel section 1. During the welding process, the monitoring and identification system 10 collects temperature, vibration error of the robotic arm 8, and deformation data in real time and feeds them back to the control system 11. The control system 11 dynamically corrects the path deviation of the robotic arm 8 according to the data, and dynamically adjusts the travel speed, posture, current and welding parameters of the welding torch 7 according to the molten pool temperature and weld width deviation.

[0109] Step 4: Upon completion of welding, the monitoring and identification system 10 identifies the weld droplet profile on the surface of the steel section 1, and the control system 11 assesses the welding quality based on the weld profile image features, and promptly addresses and repairs welding defects.

[0110] In this embodiment, automatic operation can be set up. During automatic operation, the operator can sit in a seat and follow to monitor and directly intervene in case of abnormalities. After the welding quality assessment, for qualified welds, the industrial control computer 111 synchronously generates electronic welding records to make them traceable. The records include component name, component number, weld number, welding material, process parameters, quality status, etc. For the welding of full penetration groove welds, after the root pass is completed, a quality inspection is carried out. After confirming that there are no obvious defects at the root, multi-layer and multi-pass welding is carried out. When completed, the weld size and weld leg height are checked to ensure that they meet the requirements of the drawings and relevant specifications. If there are damaged parts, they should be repaired by welding and then ground. 48 hours after the welding is completed, ultrasonic non-destructive testing is carried out. After the non-destructive testing is qualified, the weld area is coated with paint.

[0111] Although embodiments of the present invention have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A continuous climbing automatic welding robot for structural steel, characterized in that, include: The system comprises a continuous climbing mechanism (2), a synchronous lifter (4), a welding disc (6), a monitoring and identification system (10), a control system (11), and multiple rotary drive mechanisms (3). The continuous climbing mechanism (2) is movably installed on the outside of the steel section (1). The synchronous lifter (4) is installed on the upper side of the continuous climbing mechanism (2). The multiple rotary drive mechanisms (3) are movably connected to the synchronous lifter (4) through horizontal displacement mechanisms (5). The welding disc (6) is installed on the synchronous lifter (4). The output end of the rotary drive mechanism (3) is connected to a robotic arm (8). The output end of the robotic arm (8) is connected to a robotic hand (9). The robotic hand (9) holds a welding torch (7). The control system (11) is connected to the continuous climbing mechanism (2), the rotary drive mechanism (3), the synchronous lifter (4), the horizontal displacement mechanism (5), the welding torch (7), the robotic arm (8), the robotic hand (9), and the monitoring and identification system (10). The continuous climbing mechanism (2) is used for continuous lifting and lowering on the steel section (1); The rotary drive mechanism (3) is used to control the rotation of the robotic arm (8); The synchronous lifter (4) is used to drive the horizontal displacement mechanism (5) to perform vertical lifting; The horizontal displacement mechanism (5) is used to drive the rotary drive mechanism (3) to move horizontally; The welding tray (6) is used to store welding wire; The welding torch (7) is used to guide the welding wire, melt the welding wire to form a molten pool, and fill the weld seam on the steel section (1) to complete the welding. The robotic arm (8) is used to adjust the angle and position of the welding torch (7) so that it is aligned with the weld seam of the steel section (1); The robotic arm (9) is used to hold the welding torch (7); The monitoring and identification system (10) is used to obtain the tilt angle and displacement distance of the welding torch (7), identify the surface features and weld contour features of the steel section (1), collect the molten pool temperature, deformation data and mechanical arm vibration error during welding; The control system (11) is used to control the monitoring and identification system (10) to scan the surface of the steel section (1) and generate the initial welding trajectory of the welding torch (7) according to the weld position, establish an independent spatial coordinate system and generate the welding path of the welding torch (7); according to the welding path, control the continuous climbing mechanism (2), the rotary drive mechanism (3), the synchronous lifter (4), the horizontal displacement mechanism (5), the robotic arm (8), and the robotic hand (9) to work together so that the welding torch (7) moves at a constant speed according to the planned welding path when moving horizontally, vertically, and obliquely, while the angle and distance between its head and the weld remains unchanged; correct the path deviation of the welding torch (7) according to the vibration error and deformation data of the robotic arm; dynamically adjust the traveling speed, posture, current magnitude and welding parameters of the welding torch (7) according to the molten pool temperature and weld width deviation; and conduct quality assessment according to the weld droplet profile on the surface of the steel section (1).

2. The automatic welding robot for continuous climbing of structural steel according to claim 1, characterized in that: The continuous climbing mechanism (2) includes a frame (21), a first roller (210), a second roller (211), a synchronous chain (212), a first sprocket (213), a second sprocket (214), a drive sprocket (215), and a drive motor (216). The frame (21) is arranged on the outside of the profile steel (1). The first roller (210) and the second roller (211) are respectively rotatably connected to the frame (21) and respectively attached to the front and rear sides of the profile steel (1). The first sprocket (213) and the second sprocket (214) are respectively attached to the front and rear sides of the profile steel (1). 14) Connected to one end of the first roller (210) and the second roller (211) respectively, the drive motor (216) is mounted on the frame (21), the drive sprocket (215) is connected to the output end of the drive motor (216), the drive sprocket (215) and the second sprocket (214) are respectively meshed and connected to the inner side of the synchronous chain (212), the first sprocket (213) is meshed and connected to the outer side of the synchronous chain (212), and a seat (226) is connected to one side of the frame (21).

3. The automatic welding robot for continuous climbing of structural steel according to claim 2, characterized in that: The frame (21) includes a limiting plate (221) and two parallel first mounting plates (22) and second mounting plates (23). The first mounting plates (22) and second mounting plates (23) are connected to each other by two horizontal plates (24). The two ends of the first roller (210) and the second roller (211) are rotatably connected to the limiting plate (221) and the second mounting plate (23) respectively. The two ends of the limiting plate (221) are respectively sleeved on the first roller (210) and the second roller (211). The outer side of the limiting plate (221) abuts against two limiting plates. The two limiting nuts (228) are threaded to the other ends of the first roller (210) and the second roller (211), respectively. The limiting plate (221) together with the first roller (210), the second roller (211) and the second mounting plate (23) forms a slot (25) for accommodating the steel section (1). The limiting plate (221) has two positioning holes (28). The first mounting plate (22) is connected and fixed to the two positioning holes (28) on the limiting plate (221) by two positioning pins (29).

4. The automatic welding robot for continuous climbing of structural steel according to claim 1, characterized in that: The rotary drive mechanism (3) includes a rotary motor (31), a vertical gear (32), and a gear disk (33). The rotary motor (31) is mounted on the horizontal displacement mechanism (5). The vertical gear (32) is mounted on the output end of the rotary motor (31). The gear disk (33) is rotatably connected to the horizontal displacement mechanism (5) and meshed with the vertical gear (32). The bottom of the robotic arm (8) is connected to the gear disk (33).

5. The automatic welding robot for continuous climbing of structural steel according to claim 2, characterized in that: The synchronous lifter (4) includes four bases (41) and a servo motor (48). The four bases (41) are respectively connected to the upper side of the frame (21) and arranged in an array. A column (42) is vertically connected to the upper side of each base (41). A double-sided rack (43) is connected to the adjacent two sides of the column (42). A displacement seat (44) is fitted on the outer circumference of the column (42). A cavity (45) is opened in the displacement seat (44). A gear shaft (46) is rotatably connected between two adjacent displacement seats (44). The two ends of the gear shaft (46) pass through the two adjacent displacement seats (44) respectively. The seat (44) is located in the two cavities (45). Both ends of the gear shaft (46) are connected to spur gears (47) and bevel gears (49). The two spur gears (47) are respectively meshed with one side of the two adjacent double-sided racks (43). The bevel gears (49) on the two adjacent gear shafts (46) are meshed with each other. The servo motor (48) is mounted on one of the displacement seats (44) and its output shaft passes through the displacement seat (44) and is coaxially connected to the end of one of the gear shafts (46). The servo motor (48) is connected to the control system (11).

6. The automatic welding robot for continuous climbing of structural steel according to claim 5, characterized in that: The horizontal displacement mechanism (5) includes a guide rail (52), a linear reciprocating motor (51), a sliding plate (53), and a slide rail (54). The guide rail (52) and the slide rail (54) are both connected between two displacement seats (44) along the long side. The linear reciprocating motor (51) is slidably connected to the outer periphery of the guide rail (52). One side of the sliding plate (53) is connected to the linear reciprocating motor (51), and the other side of the sliding plate (53) is slidably connected to the outer side of the slide rail (54). The linear reciprocating motor (51) is connected to the control system (11).

7. The automatic welding robot for continuous climbing of structural steel according to claim 4, characterized in that: The robotic arm (8) includes a first link (81), a second link (82), a first connecting plate (83), a second connecting plate (84), a first electric push rod (85), a third link (86), a fourth link (87), a third connecting plate (88), a second electric push rod (89), and a connecting spring (810). The first connecting plate (83) is connected to the upper side of the gear plate (33). One end of the first link (81) and the second link (82) are respectively hinged to the first connecting plate (83), and the other end of the first link (81) and the second link (82) are respectively hinged to the second connecting plate (84). The movable end of the first electric push rod (85) is hinged to the second link (82), and the fixed end of the first electric push rod (85) is hinged to the first link (81). One end of the third link (86) and the fourth link (87) are respectively hinged to the second connecting plate (84), and the other end of the third link (86) and the fourth link (87) are respectively hinged to the third connecting plate (88). One end of the connecting spring (810) is connected to the third link (86), and the other end of the connecting spring (810) is connected to the fourth link (87). The fixed end of the second electric push rod (89) is hinged to the first link (81), and the movable end of the second electric push rod (89) is hinged to the fourth link (87). The bottom end of the mounting base (91) of the robot (9) is hinged to the third connecting plate (88), and the top end of the mounting base (91) is hinged to the upper part of the third link (86) through the third electric push rod (811).

8. The automatic welding robot for continuous climbing of structural steel according to claim 1, characterized in that: The robotic arm (9) includes a mounting base (91), a servo cylinder (92), a mounting frame (95), multiple support rods (93), and multiple connecting rods (96). One side of the mounting base (91) is connected to the end of the robotic arm (8). The servo cylinder (92) is mounted on the other side of the mounting base (91). The piston rod (921) of the servo cylinder (92) passes through the mounting frame (95) and is rotatably connected to a mounting block (94). A stop block (98) is mounted on the outer circumferential surface of the piston rod (921) of the servo cylinder (92). The mounting frame (95) is located outside the piston rod (921), and the inner side of the mounting frame (95) is open along the axial direction of the piston rod (921). A spiral groove (951) matching the stop (98) is provided, the stop (98) is slidably connected to the spiral groove (951), a plurality of support rods (93) are evenly arranged on the mounting frame (95) in the circumferential direction, one end of the support rod (93) is hinged to the mounting frame (95), and the other end of the support rod (93) is connected to a replaceable claw (97), the plurality of replaceable claws (97) abut against the outside of the welding torch (7), a plurality of connecting rods (96) correspond one-to-one with the plurality of support rods (93), one end of the plurality of connecting rods (96) is respectively hinged to the mounting block (94) in the circumferential direction, and the other end of the plurality of connecting rods (96) is hinged to the support rod (93).

9. The automatic welding robot for continuous climbing of structural steel according to claim 1, characterized in that: The welding torch (7) includes a torch body (71), two clamping blocks (72), and a conductive nozzle (75). The torch body (71) has a gas and wire feeding channel (74) extending through the outer shell along its length. The conductive nozzle (75) is located at the front of the torch body (71). The two clamping blocks (72) are symmetrically arranged at the rear of the torch body (71). One of the clamping blocks (72) is connected to the inner wall of the torch body (71) via a spring (73). Each clamping block (72) has three rollers (76) rotatably connected to it. The outer circumferential surface of each roller (76)... A roller (77) is connected, and a gap is provided between two adjacent rollers (77) for the welding wire to pass through. Three rollers (76) on another clamping block (72) pass through the gun body (71) and are sequentially fitted with a drive gear (78), an idler gear (79), and a driven gear (710). The drive gear (78) and the driven gear (710) rotate synchronously with the rollers (77). The idler gear (79) is meshed with the drive gear (78). The driven gear (710) rotates synchronously with the drive gear (78) through the idler gear (79).

10. A welding method for a continuous climbing automatic welding robot for structural steel as described in claim 1, characterized in that: The welding method includes the following steps: Step 1: Install the continuous climbing mechanism (2) on the outside of the steel section (1), then install the synchronous lifting device (4) on the continuous climbing mechanism (2), and install the horizontal displacement mechanism (5), the rotary drive mechanism (3), the robotic arm (8), the robotic hand (9), the welding torch (7), the monitoring and identification system (10), and the control system (11) in sequence. Step 2: Preset welding process library and establish welding space rectangular coordinate system. Use monitoring and recognition system (10) to scan the surface of steel section (1) and perform three-dimensional modeling to identify weld seam and generate initial welding trajectory. The industrial control computer (111) in control system (11) controls the equipment to simulate pre-action and controls the continuous climbing mechanism (2) to continuously climb on steel section (1). Control the continuous climbing mechanism (2), rotary drive mechanism (3), synchronous lifter (4), horizontal displacement mechanism (5), robotic arm (8), and robotic hand (9) to work together to make the head of welding torch (7) move along the initial welding trajectory. During the movement, the monitoring and recognition system (10) automatically judges whether the welding torch (7) is moving along the center of weld seam. At the same time, the industrial control computer (111) in control system (11) calculates the three-dimensional coordinates of the head of welding torch (7) based on the data collected by monitoring and recognition system (10) to verify whether the welding path is correct. The image and three-dimensional coordinates identified by monitoring and recognition system (10) are parallel dual control to make the welding torch (7) move at a constant speed along the predetermined welding path and maintain a preset relative distance with the weld seam. Step 3: The control system (11) controls the continuous climbing mechanism (2) to fall back to the starting position. According to the welding path, the control system controls each mechanism to carry out the assembly line operation, so that the welding gun (7) moves at a constant speed according to the planned welding path when moving horizontally, vertically and obliquely, and performs uniform welding on the weld of the steel section (1). During the welding process, the monitoring and identification system (10) collects temperature, mechanical arm (8) vibration error and deformation data in real time and feeds them back to the control system (11). The control system (11) dynamically corrects the path deviation of the mechanical arm (8) according to the data, and dynamically adjusts the travel speed, posture, current and welding parameters of the welding gun (7) according to the molten pool temperature and weld width deviation. Step 4: Upon completion of welding, the monitoring and identification system (10) identifies the weld droplet profile on the surface of the steel section (1), and the control system (11) evaluates the welding quality based on the characteristics of the weld profile image, and promptly handles and repairs welding defects.

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