Welding apparatus and welding method for a dolly bridge

Abstract

This invention relates to the field of welding equipment, specifically to a welding device and method for German-style bridges. The welding device for German-style bridges includes: a fixed clamping structure comprising a fixed body and a fixed oil seal positioning sleeve mounted on the fixed body; a movable clamping structure comprising a movable body and a movable oil seal positioning sleeve mounted on the movable body; a lifting and adjusting structure comprising a lifting seat arranged between the fixed body and the movable body, and a limiting seat and rollers mounted on the lifting seat; a base plate positioning structure comprising a positioning bushing mounted on the fixed body and the movable body, an expansion sleeve arranged at one end of the positioning bushing, a telescopic tension rod arranged within the positioning bushing, and a frustum-shaped portion arranged at the end of the tension rod and cooperating with the expansion sleeve; a ball support positioning structure; and a gas chamber support positioning structure. The welding device for German-style bridges of this invention simplifies the welding process, reduces repetitive positioning, and improves welding efficiency and welding accuracy.

Description

Technical Field

[0001] This invention relates to the field of welding equipment, and more specifically to a welding device and welding method for German-style bridges. Background Technology

[0002] The base plates at both ends of the German-style axle tube need to be assembled and welded onto the tube first, and then welded. The axle tube is square-shaped, with oil seal positions formed at both ends.

[0003] Chinese invention patent CN104308440B discloses a welding robot for positioning air chamber seats, including a crossbeam, left and right slide table assemblies, left and right axle rotation positioning assemblies for rotating and positioning the axle, left and right brake base plate positioning assemblies for positioning the brake base plate, and left and right air chamber seat positioning assemblies for positioning the air chamber seat. The brake base plate is positioned by the left and right brake base plate positioning assemblies, thereby positioning the axle. However, this welding robot for positioning air chamber seats requires first welding the brake base plate to the axle, and then hoisting the axle, after welding the brake base plate, onto the welding robot for welding the air chamber seat. This process is cumbersome, has low welding efficiency, and cannot achieve continuous welding of the bridge tube, base plate, and air chamber seat.

[0004] Therefore, a new technical solution is needed in this field to solve the above problems. Summary of the Invention

[0005] To improve or solve the technical problems of cumbersome welding process and low welding efficiency in existing welding robots, this invention provides a welding device for German-style bridges. The welding device for German-style bridges includes: a fixed clamping structure, including a fixed body and a fixed oil seal positioning sleeve mounted on the fixed body; a movable clamping structure, including a movable body arranged opposite to the fixed body and movable towards or away from the fixed body, and a movable oil seal positioning sleeve mounted on the movable body; a lifting and adjusting structure, including a lifting seat arranged between the fixed body and the movable body, and a limiting seat and rollers mounted on the lifting seat; a base plate positioning structure, including a positioning bushing mounted on the fixed body and the movable body, an expansion sleeve arranged at one end of the positioning bushing, a telescopic tension rod arranged within the positioning bushing, and a frustum portion arranged at the end of the tension rod and cooperating with the expansion sleeve; a ball support positioning structure arranged on one side of the lifting and adjusting structure; and a gas chamber support positioning structure arranged on the other side of the lifting and adjusting structure.

[0006] The welding equipment for German-style bridges of this invention includes a fixed clamping structure, a movable clamping structure, a lifting and adjusting structure, a base plate positioning structure, a ball support positioning structure, and a gas chamber support positioning structure. The lifting and adjusting structure supports and limits the bridge tube; the limiting seat limits both sides of the bridge tube, and the rollers support the bridge tube and facilitate its movement. The fixed clamping structure serves as a positioning reference for the bridge tube, positioning and clamping one end of the tube. The fixed oil seal positioning sleeve mates with the oil seal position at the end of the bridge tube, thus positioning and clamping one end of the bridge tube when the oil seal position is in contact with the fixed oil seal positioning sleeve. The movable clamping structure pushes the bridge tube towards the fixed clamping structure and positions and clamps the other end of the bridge tube. The movable oil seal positioning sleeve mates with the oil seal position at the other end of the bridge tube. When the fixed oil seal positioning sleeve and the movable oil seal positioning sleeve are respectively in contact with the oil seal positions at both ends of the bridge tube, the bridge tube is positioned and clamped. The base plate positioning structure is used to position and clamp the base plate. Installed on both the fixed and moving bodies, the base plate is automatically positioned once the bridge tube is clamped, resulting in a simple, convenient, and accurate positioning method. The base plate positioning structure includes a positioning bushing, an expansion sleeve, a tension rod, and a frustum section. The base plate is clamped by tightening the expansion sleeve, preventing tilting and ensuring positioning accuracy. The ball support positioning structure and the gas chamber support positioning structure are arranged on both sides of the lifting and adjusting structure. After the base plate and bridge tube are positioned, the ball support and gas chamber support are attached to the bridge tube for subsequent assembly and welding. Through the above configuration, the welding equipment for German-style bridges of this invention uses a fixed clamping structure and a moving clamping structure to position and clamp the bridge tube, a base plate positioning structure to position and clamp the base plate, and a ball support positioning structure and a gas chamber support positioning structure to position and clamp the ball support and gas chamber support. This simplifies the welding process, reduces repetitive positioning, and improves welding efficiency and accuracy.

[0007] Furthermore, it also includes a frame; a side-push cylinder is provided on the side of the moving body away from the fixed body, and a sliding guide rail is provided on the frame to limit the sliding direction of the moving body; the limiting seat includes a first limiting plate and a second limiting plate arranged opposite to each other and located on both sides of the bridge tube. Through the above configuration, the side-push cylinder and the sliding rail can strictly constrain the movement direction of the moving body, ensuring that the fixed oil seal positioning sleeve and the moving oil seal positioning sleeve always remain coaxial, thereby ensuring the positioning accuracy of the bridge tube.

[0008] Furthermore, the ball support positioning structure includes a first XY-axis slide mounted on the frame and a ball support fixing plate mounted on the first XY-axis slide; the air chamber support positioning structure includes a second XY-axis slide mounted on the frame and an air chamber support fixing plate mounted on the second XY-axis slide. Through the above configuration, the first XY-axis slide and the second XY-axis slide can be conveniently adjusted to adjust the positions of the ball support and the air chamber support, thereby facilitating their positioning.

[0009] Furthermore, a positioning surface is formed at the end of the positioning bushing near the expansion sleeve, and the tension rod is connected to a driving component; three sets of the base plate positioning structure are provided on both the fixed body and the moving body. Through the above arrangement, the positioning surface can provide a positioning reference for the base plate, ensuring the positioning accuracy of the base plate and reducing the adjustment time for base plate placement; the coordinated action of multiple sets of base plate positioning structures can simultaneously position multiple positions of the base plate, further improving the positioning accuracy and clamping stability of the base plate.

[0010] Furthermore, a contact digital sensor suitable for abutting against the base plate is provided on the positioning bushing, and a 3D scanner is mounted on the frame. Through these configurations, the contact digital sensor can monitor the contact status between the base plate and the positioning bushing in real time, ensuring accurate positioning of the base plate; the 3D scanner can scan the assembly model of the German bridge and welding device, facilitating monitoring of the assembly status of the German bridge, thereby ensuring the positioning accuracy of the German bridge.

[0011] To improve or solve the problems of cumbersome welding processes and low welding efficiency in existing welding robots, this invention provides a welding method for German-style bridges. The welding method for German-style bridges includes: controlling the lifting and adjusting structure to raise and lower, adjusting the position of the bridge tube to be aligned with the fixed oil seal positioning sleeve and the movable oil seal positioning sleeve; controlling the base plate positioning structure to position and clamp the base plate; controlling the movable clamping structure to move closer to the fixed clamping structure, so that the oil seal positions at both ends of the bridge tube are respectively in contact with the fixed oil seal positioning sleeve and the movable oil seal positioning sleeve; controlling the ball support positioning structure and the gas chamber support positioning structure to move the ball support and the gas chamber support to fit the bridge tube; and controlling the welding robot to perform assembly welding on the bridge tube, the base plate, the ball support, and the gas chamber support.

[0012] In the welding method for German-style bridges of the present invention, the bridge tube is positioned and clamped by a fixed clamping structure and a movable clamping structure, the base plate is positioned and clamped by a base plate positioning structure, and the ball support and gas chamber support are positioned and clamped by a ball support positioning structure and a gas chamber support positioning structure. This simplifies the welding process, reduces repeated positioning, and improves welding efficiency and welding accuracy.

[0013] Furthermore, the step of controlling the base plate positioning structure to position and clamp the base plate includes: fitting the base plate onto the expansion sleeve of the base plate positioning structure; controlling the driving component to tighten the expansion sleeve by driving the truncated cone portion; acquiring the contact state of the contact digital sensors and determining the positioning state of the base plate based on the contact state; determining that the base plate is accurately positioned when all three contact digital sensors are in a stable triggered state; determining that the base plate is inaccurately positioned when any of the three contact digital sensors are in an untriggered state, and issuing a base plate tilt alarm. Through the above settings, the positioning state of the base plate is automatically determined by the contact state of the sensors, and an alarm is issued when an abnormality occurs, which can avoid welding rework caused by positioning problems, improve the first-pass welding qualification rate, and thus improve the overall welding efficiency. Judging based on the state of the three contact digital sensors can improve the positioning accuracy and reliability of the base plate.

[0014] Furthermore, the step of controlling the moving clamping structure to approach the fixed clamping structure, and having the oil seals at both ends of the bridge tube respectively engage with the fixed oil seal positioning sleeve and the moving oil seal positioning sleeve, includes: obtaining a preset extension length of the bridge tube end extending beyond the fixed body and the actual extension length of the bridge tube end extending beyond the fixed body; determining the positioning state of the bridge tube based on the preset extension length and the actual extension length; when the actual extension length and the preset extension length are equal, the oil seals at both ends of the bridge tube engage with the fixed oil seal positioning sleeve and the moving oil seal positioning sleeve respectively; when the actual extension length is less than the preset extension length, the oil seals of the bridge tube are not engaged with the fixed oil seal positioning sleeve. Through the above settings, using the fixed body as the positioning reference and the extension length as the judgment criterion, the positioning state of the bridge tube can be accurately quantified. After the side-push cylinder stops moving, the positioning state of the bridge tube is checked to ensure that the oil seals at both ends of the bridge tube are completely engaged with the positioning sleeve, ensuring accurate positioning of the bridge tube and improving overall welding accuracy.

[0015] Furthermore, after the step of determining that the oil seal of the bridge tube and the fixed oil seal positioning sleeve are not in contact when the actual extension length is less than the preset extension length, the method further includes: obtaining the preset distance between the fixed body and the moving body, and the actual distance between the fixed body and the moving body; determining the working state of the side thrust cylinder based on the preset distance and the actual distance; determining that the side thrust cylinder is working normally when the actual distance is equal to the preset distance; determining that the side thrust cylinder is abnormal when the actual distance is greater than the preset distance, and issuing a side thrust cylinder abnormality alarm. Through the above settings, by comparing the actual distance with the preset distance, it is possible to accurately determine whether the side thrust cylinder is working normally. If the distance is normal, the bridge tube is abnormal; if the distance is abnormal, the side thrust cylinder is abnormal. When an abnormality occurs during the assembly process, the cause of the abnormality can be further analyzed, avoiding the investigation of irrelevant components, thereby improving the efficiency and accuracy of fault diagnosis.

[0016] Furthermore, the step of obtaining the preset extension length of the bridge tube end extending beyond the fixing body and the actual extension length of the bridge tube end extending beyond the fixing body includes: obtaining a three-dimensional standard model of the German-style bridge and the welding equipment; obtaining the preset extension length of the bridge tube end extending beyond the fixing body based on the three-dimensional standard model; acquiring a paired model of the German-style bridge and the welding equipment; and obtaining the actual extension length of the bridge tube end extending beyond the fixing body based on the paired model. Through the above settings, the three-dimensional model and the paired model can conveniently obtain the preset extension length and the actual extension length, facilitating rapid comparison of length data and improving positioning verification efficiency. Attached Figure Description

[0017] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, in which:

[0018] Figure 1 This is a schematic diagram of an embodiment of the welding equipment of the present invention for German-style bridges;

[0019] Figure 2 This is a front view of an embodiment of the welding equipment for German-style bridges according to the present invention;

[0020] Figure 3 This is a top view of an embodiment of the welding equipment for German-style bridges according to the present invention;

[0021] Figure 4 This is a side view of an embodiment of the welding equipment for German-style bridges according to the present invention;

[0022] Figure 5 This is a schematic diagram of an embodiment of the lifting and adjusting structure used in the welding equipment for German-style bridges according to the present invention;

[0023] Figure 6This is a schematic diagram of an embodiment of the bottom plate positioning structure in the welding equipment for German-style bridges according to the present invention;

[0024] Figure 7 This is a schematic diagram of an embodiment of the ball support positioning structure in the welding equipment for German-style bridges according to the present invention;

[0025] Figure 8 This is a schematic diagram of an embodiment of the gas chamber support positioning structure in the welding equipment for German-style bridges according to the present invention;

[0026] Figure 9 This is a flowchart of an embodiment of the welding method of the present invention for German-style bridges.

[0027] List of reference numerals in the attached drawings: 1. Frame; 11. Sliding guide rail; 2. Fixed clamping structure; 21. Fixed body; 211. Fixed part; 212. Mounting part; 22. Fixed oil seal positioning sleeve; 3. Moving clamping structure; 31. Moving body; 311. Sliding part; 312. Moving part; 32. Moving oil seal positioning sleeve; 33. Side push cylinder; 34. Cylinder seat; 35. Connecting seat; 4. Lifting and adjusting structure; 41. Lifting seat; 42. Limiting seat; 421. First limiting plate; 422. Second limiting plate; 43. Roller; 44. Lifting cylinder; 5. Base plate positioning structure; 51. Positioning bushing; 511. Positioning surface; 52. Expansion sleeve; 53. Tension rod; 54. Conical part; 55. Driving component; 56. Mounting seat; 6. Ball bracket positioning structure; 61. First XY axis slide; 62. Ball bracket fixing plate; 7. Air chamber bracket positioning structure; 71. Second XY axis slide; 72. Air chamber bracket fixing plate; 73. Clamping plate; 74. Positioning pin. Detailed Implementation

[0028] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0029] It should be noted that in the description of this invention, terms such as "upper," "lower," "left," "right," "inner," and "outer," indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "setting," and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection, an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0031] In order to improve or solve the technical problems of cumbersome welding process and low welding efficiency of welding robots in the prior art, the present invention provides a welding device for German bridges. The welding equipment for German-style bridges includes: a fixed clamping structure 2, comprising a fixed body 21 and a fixed oil seal positioning sleeve 22 mounted on the fixed body 21; a movable clamping structure 3, comprising a movable body 31 arranged opposite to the fixed body 21 and capable of approaching or moving away from the fixed body 21, and a movable oil seal positioning sleeve 32 mounted on the movable body 31; a lifting and adjusting structure 4, comprising a lifting seat 41 arranged between the fixed body 21 and the movable body 31, and a limiting seat 42 and a roller 43 mounted on the lifting seat 41; a base plate positioning structure 5, comprising a positioning bushing 51 mounted on the fixed body 21 and the movable body 31, an expansion sleeve 52 arranged at one end of the positioning bushing 51, a telescopic tension rod 53 arranged within the positioning bushing 51, and a frustum portion 54 arranged at the end of the tension rod 53 and cooperating with the expansion sleeve 52; a ball support positioning structure 6, arranged on one side of the lifting and adjusting structure 4; and a gas chamber support positioning structure 7, arranged on the other side of the lifting and adjusting structure 4.

[0032] Figure 1 This is a schematic diagram of an embodiment of the welding equipment for German-style bridges according to the present invention. Figure 1 As shown, in one or more embodiments, the welding equipment for German bridges of the present invention includes a frame 1, a fixed clamping structure 2, a movable clamping structure 3, a lifting and adjusting structure 4, a base plate positioning structure 5, a ball support positioning structure 6, and a gas chamber support positioning structure 7.

[0033] Figure 2 This is a front view of an embodiment of the welding equipment for German-style bridges according to the present invention. Figure 3 This is a top view of an embodiment of the welding equipment for German-style bridges according to the present invention. Figure 4 This is a side view of an embodiment of the welding equipment for German-style bridges according to the present invention. Figures 1 to 4As shown, the frame 1 serves as the supporting foundation for the entire welding equipment, providing a stable and rigid platform to support and secure all structural components of the equipment, ensuring overall structural stability during operation. For example, the frame 1 can be implemented in various forms, such as a frame structure welded from high-strength steel or a one-piece base formed using a casting process. Furthermore, a sliding guide rail 11 is provided at the left end of the frame 1, extending along the length of the frame 1. Figure 1 As shown in the diagram, the fixed clamping structure 2 is located at the right end of the frame 1, the movable clamping structure 3 is located in the middle left of the frame 1, the lifting adjustment structure 4 is located in the middle of the frame 1 in the front-back direction, the ball support positioning structure 6 is located in front of the lifting adjustment structure 4 in the front-back direction, and the air chamber support positioning structure 7 is located behind the lifting adjustment structure 4 in the front-back direction.

[0034] See also Figures 1 to 4 The fixed clamping structure 2 serves as a positioning reference for the bridge tube, used to position and clamp one end of the bridge tube. In one or more embodiments, the fixed clamping structure 2 includes a fixing body 21 fixed to the frame 1 and a fixed oil seal positioning sleeve 22 mounted on the fixing body 21. Specifically, the fixing body 21 includes a fixing part 211 fixed to the frame 1 by bolts and a mounting part 212 vertically mounted on the fixing part 211. A through hole matching the fixed oil seal positioning sleeve 22 is provided on the mounting part 212, and bolt holes are provided along the circumference of the through hole. The fixed oil seal positioning sleeve 22 is mounted at the through hole by bolts. The fixed oil seal positioning sleeve 22 extends partially into the through hole, and the inner wall of the fixed oil seal positioning sleeve 22 matches the shape of the oil seal position of the bridge tube. The right end of the bridge tube passes through the fixed oil seal positioning sleeve 22 and the mounting part 212, and the oil seal position fits against the inner wall of the fixed oil seal positioning sleeve 22. Furthermore, a reinforcing plate is provided between the fixing part 211 and the mounting part 212 to enhance the structural stability of the fixing body 21.

[0035] See also Figures 1 to 4The movable clamping structure 3 pushes the bridge tube towards the fixed clamping structure 2 and positions the other end of the bridge tube. In one or more embodiments, the movable clamping structure 3 is slidably mounted on the frame 1. The movable clamping structure 3 includes a movable body 31 that is slidably connected to the sliding guide rail 11, and a movable oil seal positioning sleeve 32 mounted on the movable body 31. The movable body 31 includes a sliding part 311 that is slidably connected to the sliding guide rail 11, and a movable part 312 connected to the sliding part 311. The structure of the movable part 312 is the same as that of the fixed body 21, and the structures of the movable oil seal positioning sleeve 32 and the fixed oil seal positioning sleeve 22 are the same, and will not be described again here. Further, a side-push cylinder 33 is provided at the left end of the frame 1, and the side-push cylinder 33 is connected to the movable body 31. Specifically, a cylinder seat 34 is provided at the left end of the frame 1, and the side-push cylinder 33 is mounted on the cylinder seat 34. A connecting seat 35 is provided on the movable body 31. The connecting seat 35 includes an upper support plate, a lower support plate, and a connecting support plate connecting the upper support plate and the lower support plate, which are arranged opposite to each other. Both the upper support plate and the lower support plate extend from the movable body 31 in the direction of the side-push cylinder 33. The cylinder shaft of the side-push cylinder 33 is connected to the connecting support plate.

[0036] Figure 5 This is a schematic diagram of an embodiment of the lifting and adjusting structure used in the welding equipment for German-style bridges according to the present invention. Figures 1 to 5As shown, the lifting adjustment structure 4 is arranged between the fixed body 21 and the movable body 31. In one or more embodiments, two sets of lifting adjustment structures 4 are provided, and the two sets of lifting adjustment structures 4 are arranged at intervals along the length direction of the frame 1. Each set of lifting adjustment structures 4 includes a lifting seat 41, and a limiting seat 42 and a roller 43 installed on the lifting seat 41. Specifically, a cylinder seat 34 is installed on the frame 1, and a lifting cylinder 44 is installed below the cylinder seat 34. The cylinder shaft of the lifting cylinder 44 passes through the cylinder seat 34 and is connected to the lifting seat 41, thereby driving the lifting seat 41 to rise and fall. Further, a guide sleeve is provided on the cylinder seat 34, and a guide post that matches the guide sleeve is provided on the lifting seat 41. The guide post is slidably arranged inside the guide sleeve. Furthermore, a limiting seat 42 is arranged on the left side of the lifting seat 41. The limiting seat 42 includes a first limiting plate 421 and a second limiting plate 422 arranged opposite to each other in the front-rear direction. A gap is formed between the first limiting plate 421 and the second limiting plate 422 to accommodate the bridge tube, thereby limiting the bridge tube in the front-rear direction of the frame 1 and ensuring the positioning accuracy of the bridge tube. Furthermore, rollers 43 are arranged on the right side of the lifting seat 41. The bridge tube is placed on the rollers 43 of the two sets of lifting adjustment structures 4, thereby facilitating the movement of the bridge tube on the rollers 43. When welding is required, the bridge tube is hoisted onto roller 43. The side-push cylinder 33 actuates, causing the moving body 31 to slide, simultaneously pushing the bridge tube towards the fixed body 21. Once the oil seal position of the bridge tube is fully aligned with the fixed oil seal positioning sleeve 22 of the fixed body 21, the bridge tube stops moving. After welding is completed, the side-push cylinder 33 reverses its action, moving the moving body 31 away from the fixed body 21 and pulling the bridge tube out of the fixed oil seal positioning sleeve 22. At this point, the bridge tube can be hoisted away from the welding equipment. Using the fixed oil seal positioning sleeve 22 and the moving oil seal positioning sleeve 32 to position the bridge tube, with the fixed oil seal positioning sleeve 22 as the reference, provides a higher positioning reference and accuracy.

[0037] Figure 6 This is a schematic diagram of an embodiment of the bottom plate positioning structure in the welding equipment for German-style bridges according to the present invention. Figures 1 to 6As shown, the base plate positioning structure 5 is installed on the fixed body 21 and the movable body 31, and is used to position and clamp the base plates on both sides of the bridge tube onto the fixed body 21 and the movable body 31. In one or more embodiments, six sets of base plate positioning structures 5 are provided, of which three sets of base plate positioning structures 5 are installed on the fixed body 21 and the other three sets of base plate positioning structures 5 are installed on the movable body 31. One set of base plate positioning structures 5 on the fixed body 21 includes a positioning bushing 51 installed on the fixed body 21, an expansion sleeve 52 arranged at one end of the positioning bushing 51, a telescopic tension rod 53 arranged in the positioning bushing 51, and a frustum portion 54 arranged at the end of the tension rod 53. The tension rod 53 is connected to a driving member 55, which is a tensioning cylinder. Specifically, a mounting seat 56 is provided on the fixed body 21, and the mounting seat 56 is installed on the fixed body 21 by bolts, and the driving member 55 is fixed on the mounting seat 56. The driving member 55 and the tension rod 53 are detachably connected by nuts. A truncated cone portion 54 is located at the end of the tension rod 53 away from the drive member 55. The truncated cone portion 54 has a large end and a small end, wherein the small end is connected to the tension rod 53, and the large end is away from the tension rod 53. Further, a flange portion is formed at the end of the positioning bushing 51 near the fixing body 21, and the flange portion is bolted to the fixing body 21. A positioning surface 511 is formed on the side of the positioning bushing 51 away from the fixing body 21 so as to abut against the base plate. An expansion sleeve 52 is formed at the end of the positioning bushing 51 away from the fixing body 21. For example, the expansion sleeve 52 is approximately four-lobed. When the conical portion moves towards the fixing body 21, the right end of the expansion sleeve 52 expands, perfectly fitting the through hole on the base plate. This not only improves positioning accuracy but also pushes the base plate towards the positioning surface 511 to a certain extent, ensuring that the base plate is tightly against the positioning surface 511, further improving the positioning accuracy of the base plate.

[0038] See also Figures 1 to 6In one or more embodiments, the other two sets of base plate positioning structures 5 on the fixed body 21 are driven by a driving component 55 to realize the positioning of the three through holes on the base plate by the three sets of expansion sleeves 52, and to clamp the base plate at the three through holes. The arrangement of the three sets of expansion sleeves 52 can ensure the positioning accuracy and clamping stability of the base plate. It is understood that the base plate positioning structure 5 on the moving body 31 is the same as the base plate fixing structure on the fixed body 21, and will not be described again here. When the base plate needs to be positioned and clamped, the base plate abuts against the positioning surface 511, the expansion cylinder is activated, driving the conical part to move inward into the expansion sleeve 52, the expansion sleeve 52 expands, thereby expanding and positioning the base plate; after welding is completed, the expansion cylinder reverses its action, driving the conical part to move outward from the expansion sleeve 52, the expansion sleeve 52 retracts, making it easy for the base plate to disengage from the expansion sleeve 52 and the conical part. Furthermore, a contact digital sensor is provided on the positioning bushing 51 to detect whether the base plate is in contact with the positioning surface 511. Each positioning bushing 51 is equipped with a contact-type digital sensor. Specifically, when the base plate is in contact with the positioning surface 511, the contact-type digital sensor comes into contact with the base plate and is triggered. Furthermore, a 3D scanner is also installed above the frame 1 to scan the welding equipment and the German bridge, thereby analyzing whether the positioning of the bridge tube, base plate, ball support, and gas chamber support is accurate enough.

[0039] Figure 7 This is a schematic diagram of an embodiment of the ball support positioning structure in the welding equipment for German-style bridges according to the present invention. Figure 1 and Figure 7 As shown, two sets of ball support positioning structures 6 are arranged along the length of the frame 1. In one or more embodiments, the ball support positioning structure 6 includes a first XY-axis slide 61 mounted on the frame 1 and a ball support fixing plate 62 mounted on the first XY-axis slide 61. Specifically, the first XY-axis slide 61 can adjust the ball support fixing plate 62 in the left-right and front-back directions to position the ball support. The ball support fixing plate 62 is approximately L-shaped, and a through hole is provided at the end of the ball support fixing plate 62 away from the first XY-axis slide 61 for placing the ball support. Further, the first XY-axis slide 61 is a manual slide, and after the ball support fixing plate 62 is adjusted, a locking block locks and fixes the ball support fixing plate 62. Alternatively, the first XY-axis slide 61 is an electric slide, which uses a motor to drive a screw to rotate, thereby realizing XY-axis adjustment.

[0040] Figure 8 This is a schematic diagram of an embodiment of the gas chamber support positioning structure in the welding equipment for German-style bridges according to the present invention. Figure 1 and Figure 8As shown, two sets of air chamber support positioning structures 7 are arranged along the length of the frame 1. In one or more embodiments, the air chamber support positioning structure 7 includes a second XY-axis slide 71 mounted on the frame 1 and an air chamber support fixing plate 72 mounted on the second XY-axis slide 71. The second XY-axis slide 71 has the same structure as the first XY-axis slide 61, and will not be described again here. Further, the air chamber support fixing plate 72 is approximately L-shaped, and a clamping plate 73 is provided at one end of the air chamber support fixing plate 72 away from the second XY-axis slide 71. A positioning pin 74 that matches the air chamber support is provided on the clamping plate 73. The air chamber support is suspended on the clamping plate 73 by the positioning pin 74.

[0041] Figure 9 This is a flowchart illustrating an embodiment of the welding method for German-style bridges according to the present invention. Figure 9 As shown, in order to improve or solve the technical problems of cumbersome welding process and low welding efficiency in existing welding robots, this invention provides a welding method for German-style bridges. This welding method for German-style bridges includes:

[0042] Step S1: Control the lifting and adjusting structure 4 to raise and lower, adjusting the position of the bridge tube to be aligned with the fixed oil seal positioning sleeve 22 and the movable oil seal positioning sleeve 32. The lifting and adjusting structure 4 includes a lifting seat 41, a lifting cylinder 44, a limit seat 42, and rollers 43. It is understood that the welding equipment is equipped with a control system connected to each structure to control their actions. Alignment of the bridge tube, fixed oil seal positioning sleeve 22, and movable oil seal positioning sleeve 32 means that their central axes are collinear. The fixed oil seal positioning sleeve 22 is installed on the fixed body 21, and the movable oil seal positioning sleeve 32 is installed on the movable body 31. The fixed oil seal positioning sleeve 22 and the movable oil seal positioning sleeve 32 are aligned during the assembly of the welding equipment. Specifically, step S1 includes:

[0043] Step S11: Obtain the 3D standard model of the German-style bridge and welding equipment. The 3D standard model is a 3D standard model of the assembled German-style bridge and welding equipment. This 3D standard model can be directly imported into the control system. For example, the 3D standard model can be opened using 3D modeling software, and its dimensions can be analyzed and annotated using the measurement tools within the software.

[0044] Step S12: Obtain the height dimension of the fixed oil seal positioning sleeve 22 and the dimension of the bridge tube, and calculate the height dimension of the roller 43 based on the height dimension of the fixed oil seal positioning sleeve 22 and the dimension of the bridge tube. The height dimension of the fixed oil seal positioning sleeve 22 refers to the height between its central axis and the working surface of the frame 1; the dimension of the bridge tube includes its length, width, height, and the length of the oil seal position; the height dimension of the roller 43 refers to the height between the highest point of the roller 43 and the working surface of the frame 1. The height dimension of the roller 43 = the height dimension of the fixed oil seal positioning sleeve 22 - half the height dimension of the bridge tube.

[0045] Step S13: Based on the height of the roller 43, control the lifting cylinder 44 to move the lifting seat 41 up and down. The lifting seat 41 moving up and down causes the limit seat 42 and the roller 43 to move up and down. The lifting cylinder 44 is connected to the control system and is controlled by the control system.

[0046] Step S14: The robot arm is controlled to lift and place the bridge tube onto the roller 43, positioned between the first limiting plate 421 and the second limiting plate 422 of the limiting seat 42. The roller 43 facilitates the sliding of the bridge tube, while the first limiting plate 421 and the second limiting plate 422 limit the front and rear sides of the bridge tube, restricting its movement direction. The robot arm is connected to the control system and controlled by the control system. The height dimensions of the fixed oil seal positioning sleeve 22, the dimensions of the bridge tube, and the height dimensions of the roller 43 can be stored in the database of the control system after a single measurement.

[0047] Step S2: Control the base plate positioning structure 5 to position and clamp the base plate. Two base plates are provided, respectively positioned and clamped on the fixed body 21 and the moving body 31. The base plate positioning structure 5 has six sets, three sets mounted on the fixed body 21 and the other three sets mounted on the moving body 31. The base plate positioning structure 5 includes a positioning bushing 51, an expansion sleeve 52, a tension rod 53, and a frustum-shaped portion 54. The expansion sleeves 52 of the three sets of base plate positioning structures 5 are tightened within the three through holes of the base plate, achieving high-precision and high-stability positioning and clamping of the base plate. Step S2 includes:

[0048] Step S21: Place the base plate onto the expansion sleeves 52 of the base plate positioning structure 5. The three through holes of the base plate correspond to the three expansion sleeves 52 of the base plate positioning structure 5, and the side of the base plate closest to the positioning bushings 51 abuts against the positioning surfaces 511 of the three positioning bushings 51, achieving precise positioning of the base plate. For example, the base plate can be loaded by a robotic arm or manually.

[0049] Step S22: Control the drive unit 55 to drive the cone portion 54 to expand and tighten the expansion sleeve 52. The drive unit 55 is an expansion cylinder. When the expansion cylinder contracts, it pulls the cone portion 54 into the expansion sleeve 52 through the tension rod 53, thereby expanding the expansion sleeve 52 and clamping the base plate.

[0050] Step S23: Obtain the contact status of the contact digital sensor and determine the positioning status of the base plate based on the contact status. One contact digital sensor is mounted on a corresponding positioning bushing 51. The contact status is used to determine whether the base plate is in close contact with the positioning surface 511, thereby determining whether the base plate is accurately positioned. The contact status includes a triggered state and a non-triggered state. The triggered state means the base plate is in contact with the contact digital sensor, and the non-triggered state means the base plate is not in contact with the contact digital sensor. For example, when the base plate is manually loaded, the contact digital sensor is connected to an indicator light to display the contact status. An illuminated light indicates a triggered state, and an off light indicates a triggered state.

[0051] Step S24: When all three contact digital sensors are in the triggered state, it is determined that the base plate is accurately positioned.

[0052] Step S25: When any of the three contact digital sensors are in an untriggered state, it is determined that the base plate positioning is inaccurate, and a base plate tilt alarm is issued. Further, step S26 is included: acquiring the working status of the three contact digital sensors over one cycle, and determining the working status of the drive component 55 based on the working status of the contact digital sensors within one cycle; when the contact digital sensors maintain stable triggering, it is determined that the drive component 55 is working normally; when the contact digital sensors exhibit fluctuating triggering, it is determined that the drive component 55 is malfunctioning, and a drive component 55 malfunction alarm is issued. Stable triggering means that the contact digital sensor remains in a triggered state throughout one cycle. Fluctuating triggering means that the contact digital sensor switches between a triggered state and an untriggered state multiple times within one cycle. It can be understood that when one drive component 55 malfunctions, the base plate clamping on one side becomes unstable, and it may detach from the contact digital sensor when the equipment vibrates, causing the contact digital sensor to fluctuate and trigger. For example, one cycle is ten minutes, and multiple switching means switching at least twice. The time of one cycle can also be 5 minutes, 15 minutes, or other suitable times, and the specific time can be adjusted according to the welding time required. The operating status of the three contact digital sensors can be acquired after each welding operation. Alternatively, it can be acquired at intervals of half a day, a day, or other suitable intervals. Step S26 allows for further analysis of the cause of any abnormalities in the base plate positioning and clamping, avoiding the need to troubleshoot unrelated components and thus improving the efficiency and accuracy of fault diagnosis.

[0053] Step S3: Control the movable clamping structure 3 to approach the fixed clamping structure 2, so that the oil seals at both ends of the bridge tube are respectively in contact with the fixed oil seal positioning sleeve 22 and the movable oil seal positioning sleeve 32. The fixed clamping structure 2 includes a fixed body 21 and a fixed oil seal positioning sleeve 22, and the movable clamping structure 3 includes a movable body 31 and a movable oil seal positioning sleeve 32. The movable body 31 moves closer to or away from the fixed body 21 under the action of the side-push cylinder 33. The fixed oil seal positioning sleeve 22 is fixed to the frame 1 by the fixed body 21 and serves as the positioning reference for the bridge tube. When the bridge tube is pushed by the movable oil seal positioning sleeve 32, it approaches the fixed oil seal positioning sleeve 22. When the oil seal of the bridge tube is in contact with the fixed oil seal positioning sleeve 22, it is also in contact with the movable oil seal positioning sleeve 32. At this time, the bridge tube is positioned and clamped using the fixed oil seal positioning sleeve 22 as the positioning reference. Specifically, step S3 includes:

[0054] Step S31: Obtain the preset extension length of the bridge tube end extending from the fixing body 21, and the actual extension length of the bridge tube end extending from the fixing body 21. Step S31 is executed after the side-push cylinder 33 stops operating. The extension length refers to the length between the right end of the bridge tube and the left side of the fixing body 21. Specifically, step S31 includes:

[0055] Step S311: Obtain a 3D standard model of the German-style bridge and welding equipment, and obtain the preset extension length of the bridge pipe end protruding fixing body 21 based on the 3D standard model. The 3D standard model is pre-imported into the control system in step S11. The preset extension length is determined and annotated using the measurement tools of the 3D modeling software.

[0056] Step S312: Acquire the assembly model of the German-style bridge and welding equipment, and obtain the actual extension length of the bridge pipe end protruding from the fixing body 21 based on the assembly model. Specifically, the assembly model of the German-style bridge and welding equipment is acquired using a 3D scanner, imported into the control system, and the actual extension length is measured using 3D modeling software. For example, the 3D scanner is positioned above the frame 1, scanning the German-style bridge and welding equipment only from above, and the obtained assembly model is used for reference. Figure 3 .

[0057] Step S32: Determine the positioning status of the bridge tube based on the preset extension length and the actual extension length. Specifically, calculate the difference between the preset extension length and the actual extension length. When the absolute value of the difference is less than a first threshold, set the preset extension length to be equal to the actual extension length; when the absolute value of the difference is greater than or equal to the first threshold, set the actual extension length to be less than the preset extension length. For example, the first threshold is 2 mm.

[0058] Step S33: When the actual extension length and the preset extension length are equal, the oil seal positions at both ends of the bridge tube are respectively engaged with the fixed oil seal positioning sleeve 22 and the movable oil seal positioning sleeve 32. The positioning and clamping action is performed by the side-push cylinder 33 to achieve the positioning and clamping of the bridge tube; by obtaining the actual extension length and the preset extension length, it is further confirmed whether the bridge tube is accurately positioned, thereby ensuring the welding quality of the German-style bridge.

[0059] Step S34: When the actual extension length is less than the preset extension length, the oil seal position of the bridge tube is not in contact with the fixed oil seal positioning sleeve 22. When the misalignment occurs, there are two situations: abnormality of the side push cylinder 33 and abnormality of the bridge tube length. Abnormality of the side push cylinder 33 means that the side push cylinder 33 has not pushed the moving body 31 to the side. Abnormality of the workpiece means that the actual size of the workpiece is smaller than the standard size.

[0060] Step S35: Obtain the preset distance between the fixed body 21 and the moving body 31, as well as the actual distance between them. By comparing the preset distance and the actual distance, determine whether the side-push cylinder 33 has pushed the moving body 31 into position. The preset distance between the fixed body 21 and the moving body 31 can be obtained from the 3D standard model imported in step S11, and the actual distance can be obtained by measuring the assembled model acquired in step S312; these details will not be elaborated further here.

[0061] Step S36: Determine the working state of the side-push cylinder 33 based on the preset distance and the actual distance. The working state of the side-push cylinder 33 refers to whether it is operating normally. Specifically, the difference between the preset distance and the actual distance is calculated. When the absolute value of the difference is less than a second threshold, the preset distance is set to equal the actual distance; when the absolute value of the difference is greater than or equal to the second threshold, the actual distance is set to be greater than the preset distance. For example, the first threshold is 2 millimeters.

[0062] Step S37: When the actual distance is equal to the preset distance, it is determined that the side thrust cylinder 33 is working normally;

[0063] Step S38: When the actual distance is greater than the preset distance, the side thrust cylinder 33 is determined to be abnormal, and an alarm for abnormal side thrust cylinder 33 is issued. Specifically, the alarm can be issued through one or more methods, such as voice or light. It is understood that the preset extension length and preset distance, etc., can be stored in the database of the control system after a single measurement.

[0064] Step S4: Control the ball support positioning structure 6 and the air chamber support positioning structure 7 to move the ball support and air chamber support to fit the bridge tube. The ball support positioning structure 6 includes a first XY-axis slide 61 and a ball support fixing plate 62, and the air chamber support positioning structure 7 includes a second XY-axis slide 71 and an air chamber support fixing plate 72. Specifically, using the fixed body 21 as the positioning reference, the ball support fixing plate 62 and the air chamber support fixing plate 72 are adjusted by the first XY-axis slide 61 and the second XY-axis slide 71, thereby adjusting the position of the ball support and the air chamber support. For example, the first XY-axis slide 61 and the second XY-axis slide 71 can be driven by a servo motor or manually. It is understood that as long as the bridge tube and the base plate are accurately positioned, the ball support and the air chamber support can be positioned relatively easily and accurately.

[0065] Step S5: Control the welding robot to perform assembly welding on the bridge tube, base plate, ball support, and gas chamber support. Specifically, the welding robot sets the welding path based on the 3D standard model and the assembly model, and collects the weld position signal in real time while moving along the welding path. The welding torch posture is dynamically adjusted through a vision recognition system to ensure uniform weld formation. Generating the welding path through the 3D model and adjusting the welding torch posture through vision recognition are conventional methods in this field and will not be elaborated further here.

[0066] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A welding device for German-style bridges, characterized in that, include: The fixed clamping structure (2) includes a fixed body (21) and a fixed oil seal positioning sleeve (22) installed on the fixed body (21); The movable clamping structure (3) includes a movable body (31) arranged opposite to the fixed body (21) and capable of approaching or moving away from the fixed body (21), and a movable oil seal positioning sleeve (32) mounted on the movable body (31); The lifting adjustment structure (4) includes a lifting seat (41) arranged between the fixed body (21) and the moving body (31), and a limiting seat (42) and a roller (43) installed on the lifting seat (41); The base plate positioning structure (5) includes a positioning bushing (51) installed on the fixed body (21) and the moving body (31), an expansion sleeve (52) arranged at one end of the positioning bushing (51), a telescopic tension rod (53) arranged in the positioning bushing (51), and a frustum portion (54) arranged at the end of the tension rod (53) and cooperating with the expansion sleeve (52). The ball support positioning structure (6) is arranged on one side of the lifting and adjusting structure (4); The air chamber support positioning structure (7) is arranged on the other side of the lifting and adjusting structure (4); It also includes the rack (1); A contact digital sensor suitable for abutting against the base plate is provided on the positioning bushing (51), and a three-dimensional scanner is installed on the frame (1); The tension rod (53) is connected to a drive member (55), and the base plate positioning structure (5) is provided with three sets on both the fixed body (21) and the moving body (31).

2. The welding equipment for German-style bridges according to claim 1, characterized in that, A side-push cylinder (33) is provided on the side of the moving body (31) away from the fixed body (21), and a sliding guide rail (11) is provided on the frame (1) to limit the sliding direction of the moving body (31); the limiting seat (42) includes a first limiting plate (421) and a second limiting plate (422) arranged opposite to each other and located on both sides of the bridge tube respectively.

3. The welding equipment for German-style bridges according to claim 2, characterized in that, The ball support positioning structure (6) includes a first XY axis slide (61) mounted on the frame (1) and a ball support fixing plate (62) mounted on the first XY axis slide (61); the air chamber support positioning structure (7) includes a second XY axis slide (71) mounted on the frame (1) and an air chamber support fixing plate (72) mounted on the second XY axis slide (71).

4. The welding equipment for German-style bridges according to claim 2, characterized in that, A positioning surface (511) is formed at one end of the positioning bushing (51) near the expansion sleeve (52).

5. A welding method for German-style bridges, characterized in that, The welding equipment for German-style bridges as described in any one of claims 1-4 is used; the welding method comprises: Control the lifting and adjusting structure (4) to lift and adjust the position of the bridge tube to be aligned with the fixed oil seal positioning sleeve (22) and the movable oil seal positioning sleeve (32); Control base plate positioning structure (5) Positioning and clamping base plate; The control movement clamping structure (3) is brought close to the fixed clamping structure (2), and the oil seal positions at both ends of the bridge tube are respectively in contact with the fixed oil seal positioning sleeve (22) and the movement oil seal positioning sleeve (32); The control ball support positioning structure (6) and the air chamber support positioning structure (7) drive the ball support and the air chamber support to fit into the bridge tube; The welding robot is controlled to perform assembly welding on the bridge tube, the base plate, the ball support and the gas chamber support.

6. The welding method for German-style bridges according to claim 5, characterized in that, The steps of the control base plate positioning structure (5) for positioning and clamping the base plate include: The base plate is fitted onto the expansion sleeve (52) of the base plate positioning structure (5); The drive unit (55) is controlled to drive the frustum portion (54) to tighten the expansion sleeve (52); The contact state of the contact digital sensor is obtained, and the positioning state of the base plate is determined based on the contact state. When all three contact digital sensors are in a stable triggered state, it is determined that the base plate is accurately positioned. When any of the three contact digital sensors are in an untriggered state, it is determined that the base plate is not accurately positioned, and a base plate tilt alarm is issued.

7. The welding method for German-style bridges according to claim 5, characterized in that, The steps of controlling the moving clamping structure (3) to approach the fixed clamping structure (2), and the oil seal positions at both ends of the bridge tube respectively fitting with the fixed oil seal positioning sleeve (22) and the moving oil seal positioning sleeve (32) include: Obtain the preset extension length of the bridge tube end extending out of the fixing body (21) and the actual extension length of the bridge tube end extending out of the fixing body (21); The positioning status of the bridge tube is determined based on the preset extension length and the actual extension length; When the actual extension length is equal to the preset extension length, the oil seal positions at both ends of the bridge tube are respectively in contact with the fixed oil seal positioning sleeve (22) and the movable oil seal positioning sleeve (32); When the actual extension length is less than the preset extension length, the oil seal position of the bridge tube does not fit with the fixed oil seal positioning sleeve (22).

8. The welding method for German-style bridges according to claim 7, characterized in that, Following the step that the oil seal of the bridge tube does not fit with the fixed oil seal positioning sleeve (22) when the actual extension length is less than the preset extension length, the method further includes: Obtain the preset distance between the fixed body (21) and the moving body (31), and the actual distance between the fixed body (21) and the moving body (31); The working state of the side thrust cylinder (33) is determined based on the preset distance and the actual distance; When the actual distance is equal to the preset distance, it is determined that the side thrust cylinder (33) is working normally; When the actual distance is greater than the preset distance, the side thrust cylinder (33) is determined to be abnormal, and an alarm for abnormality of the side thrust cylinder (33) is issued.

9. The welding method for German-style bridges according to claim 8, characterized in that, The steps of obtaining the preset extension length of the bridge tube end extending out of the fixing body (21) and the actual extension length of the bridge tube end extending out of the fixing body (21) include: Obtain a three-dimensional standard model of the German-style bridge and the welding equipment, and obtain a preset extension length of the bridge tube end extending out of the fixing body (21) based on the three-dimensional standard model; Collect the assembly model of the German-style bridge and the welding equipment, and obtain the actual extension length of the bridge tube end extending out of the fixing body (21) based on the assembly model.

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