Laser wire filling welding system for automatic welding operation of side door of loading machine and operation method

Abstract

The invention discloses a laser wire filling welding system for automatic welding operation of a side door of a loading machine and an operation method. The laser wire filling welding system comprises a robot module, a displacement module, a pressing module, a tool module and a central control module. The robot module comprises a welding robot and a carrying robot; the displacement module is a three-axis displacement machine; the pressing module comprises a rotary C-shaped supporting and pressing executing mechanism, and the rotary C-shaped supporting and pressing executing mechanism is used for eliminating gaps generated due to supplied material tolerance or positioning errors; the tool module comprises a ground rail transplanting mechanism and a side door random tool; the central control module is a main control cabinet. By integrating the robot module, the displacement module, the pressing module, the tool module and the central control module, automation of welding operation of the side door of the loading machine is achieved. The system can effectively solve the problems of low production efficiency, large welding deformation, unstable welding seam quality, low automation degree and the like in a traditional welding mode.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a laser wire-filling welding system and method for automated welding operations on loader side doors. Background Technology

[0002] In the field of construction machinery manufacturing, welding of the cab side door is a core process, typically consisting of stamped inner and outer panels joined together by welding. Currently, the industry commonly uses manual gas metal arc welding (GMAW) or resistance spot welding. GMAW involves operators holding a welding torch and welding sections along the overlapping edges of the inner and outer panels. Specific steps include assembling the inner and outer panels, manual tack welding, full welding, and post-weld grinding. While some companies have attempted to introduce welding robots, these are only suitable for simple weld seams. For workpieces like loader side doors with complex three-dimensional curved surfaces and requiring strict control of the overlap gap, existing automation solutions often lack effective dynamic gap control mechanisms and high-precision real-time weld seam recognition capabilities, resulting in insufficient welding process stability and necessitating extensive manual repair and grinding after welding.

[0003] Existing technologies have significant drawbacks: low production efficiency, with cumbersome and lengthy manual welding processes that fail to meet the demands of modern mass production; poor weld quality consistency, with fluctuations in manual operating parameters easily leading to defects such as porosity and undercut; and the reliance on experience to control the overlap gap between inner and outer plates, which cannot guarantee uniformity and directly affects weld strength and sealing performance; significant welding deformation issues, with traditional heat sources requiring large inputs that cause severe thermal deformation of the workpiece, necessitating extensive and tedious post-weld correction and grinding work, significantly increasing subsequent processing costs; and insufficient automation, with key issues such as precise positioning of complex curved workpieces, dynamic weld tracking, and real-time gap control during the welding process yet to be effectively resolved, limiting the application of automated systems and still requiring frequent manual intervention. Summary of the Invention

[0004] In view of this, the present invention provides a laser wire-filling welding system for automated welding operations of loader side doors, which has the advantages of improving welding efficiency, ensuring consistent welding quality, reducing welding deformation, and significantly improving the degree of automation.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A laser wire-filling welding system for automated welding of loader side doors includes a robot module, a positioning module, a clamping module, a tooling module, and a central control module. The robot module includes a welding robot and a handling robot. The positioning module is a three-axis positioner used to clamp and adjust the workpiece's posture in space. The clamping module includes a rotary C-shaped support clamping actuator used to eliminate gaps caused by incoming material tolerances or positioning errors. The tooling module includes a ground rail transfer mechanism and a side door conforming tooling. The ground rail transfer mechanism is used to automatically transfer workpieces between the loading / unloading station and the welding station, while the side door conforming tooling is used for precise positioning and clamping of the workpiece. The central control module is the main control cabinet, and the welding robot, handling robot, three-axis positioner, rotary C-shaped support clamping actuator, ground rail transfer mechanism, and side door conforming tooling are all signal-connected to the main control cabinet.

[0007] Preferably, the welding robot is a six-axis welding robot, and the handling robot is a six-axis handling robot.

[0008] Preferably, the welding robot is equipped with a laser welding head and a weld seam recognition and tracking system at its end, the weld seam recognition and tracking system being used for precise positioning of the weld seam.

[0009] Preferably, the rotary C-shaped support clamping actuator integrates a pressure sensor and a displacement sensor; the pressure sensor is used to monitor the pressure value of the pressure head of the rotary C-shaped support clamping actuator in real time; the displacement sensor is used to monitor the displacement of the rotary C-shaped support clamping actuator in real time.

[0010] The present invention also proposes an operation method for a laser wire-filling welding system for automated welding of loader side doors, applicable to the laser wire-filling welding system for automated welding of loader side doors as described in any of the above embodiments, characterized by comprising the following steps: S1, manual pre-positioning and material loading; S2, automatic transfer and material loading; S3, workpiece positioning and weld preparation; S4, weld identification and welding; S5, material unloading and post-processing.

[0011] Preferably, step S1 specifically includes the following steps: S11, the operator separates the inner and outer plates that are fastened together, welds small parts and nuts on the inner plate, then fastens the inner and outer plates together and performs preliminary positioning welding at multiple points; S12, the preliminarily positioned workpiece is placed on the loading station of the ground rail transfer mechanism.

[0012] Preferably, step S2 specifically includes the following steps: S21, the ground rail transfer mechanism transfers the workpiece to the robot loading position; S22, the handling robot grabs the workpiece and places it in the conformal tooling on the three-axis positioner, and the pneumatic clamp of the conformal tooling automatically clamps it.

[0013] Preferably, step S3 specifically includes the following steps: S31, the three-axis positioner rotates and tilts according to the preset program to adjust the workpiece to the preset welding posture, and at the same time, the rotating C-type support clamping actuator moves to the position of the first welding point; S32, the pressure head of the rotating C-type support clamping actuator presses down, and during the pressing process, the pressure sensor monitors in real time, and stops when the pressure value reaches the preset threshold, thus completing the control of the gap.

[0014] Preferably, step S4 specifically includes the following steps: S41, the welding robot moves the laser welding head above the workpiece, the weld seam recognition and tracking system is activated, and the weld seam is accurately positioned; S42, the welding robot performs laser filler wire welding according to the predetermined trajectory; during the welding process, the three-axis positioner and the welding robot move together to maintain the welding angle; the rotating C-type support clamping actuator moves to the next weld point position for clamping according to the welding sequence.

[0015] Preferably, step S5 specifically includes the following steps: S51, after all welds are completed, the three-axis positioner is reset and the tooling fixture is released; S52, the handling robot removes the finished workpiece and places it at the unloading station of the ground rail transfer mechanism; S53, the ground rail transfer mechanism moves the workpiece out and a final inspection is carried out manually, including minor welding repairs and / or light grinding.

[0016] The beneficial effects of this invention are as follows: Compared with the prior art, this application achieves automation of the welding operation of the loader side door by integrating a robot module, a positioning module, a clamping module, a tooling module, and a central control module. This system effectively solves the problems of low production efficiency, large welding deformation, unstable weld quality, and low automation in traditional welding methods. Through the coordinated operation of each module, automatic workpiece transfer, precise posture adjustment, lap gap control, and automated welding can be achieved, thereby improving welding quality, reducing manual intervention, and increasing overall production efficiency.

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

[0018] Figure 1 This is a top view of the welding system of the present invention;

[0019] Figure 2 This is a front view of the welding system of the present invention;

[0020] Figure 3 yes Figure 2 Enlarged view of region A in the middle;

[0021] Figure 4 This is a schematic diagram of the structure of the inner plate of the workpiece according to the present invention;

[0022] Figure 5 This is a schematic diagram of the structure of the outer plate of the workpiece according to the present invention;

[0023] Figure 6 This is a schematic diagram of the conformal tooling of the present invention;

[0024] Figure 7 This is an assembly drawing of the workpiece and the conformal tooling of the present invention.

[0025] Figure Labels

[0026] 1. Ground rail transfer mechanism; 2. Handling robot; 3. Three-axis positioner; 4. Welding robot;

[0027] 5. Rotary C-type support clamping actuator; 5-1. Laser welding head; 5-2. Weld seam recognition and tracking system;

[0028] 6. Main control cabinet; 7. Inner panel; 8. Outer panel; 9. Side door conformal fixture. Detailed Implementation

[0029] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0031] The following is for reference. Figures 1 to 7 This invention describes a laser wire-filling welding system for automated welding operations on loader side doors, as described in an embodiment of the invention.

[0032] This application discloses a laser wire-filling welding system for automated welding of loader side doors, comprising: a robot module, a positioning module, a clamping module, a tooling module, and a central control module; the robot module includes a welding robot 4 and a handling robot 2; the positioning module is a three-axis positioner 3, which is used to clamp and adjust the posture of the workpiece in space; the clamping module includes a rotary C-type support clamping actuator 5, which is used to eliminate gaps caused by incoming material tolerances or positioning errors; the tooling module includes a ground rail transfer mechanism 1 and a side door conforming tooling 9, the ground rail transfer mechanism 1 is used to automatically transfer workpieces between the loading / unloading station and the welding station, and the side door conforming tooling 9 is used to accurately position and clamp the workpiece; the central control module is a main control cabinet 6, and the welding robot 4, the handling robot 2, the three-axis positioner 3, the rotary C-type support clamping actuator 5, the ground rail transfer mechanism 1, and the side door conforming tooling 9 are all signal-connected to the main control cabinet 6.

[0033] The system comprises several modules: a robot module, an automated unit integrating welding and handling functions, and an industrial robot for automated workpiece transfer and welding operations; a positioning module, a mechanical device for adjusting the workpiece's spatial orientation to ensure the welding area is in the optimal processing position; a clamping module, an actuator for locally clamping the workpiece during welding to control the overlap gap; a tooling module, an auxiliary system for automatic workpiece transfer, precise positioning, and stable clamping; and a central control module, the core unit for centralized management and coordinated control of the entire welding system, responsible for signal exchange and action command issuance between modules.

[0034] Furthermore, the three-axis positioner 3 is a device with at least three degrees of freedom, capable of adjusting the complex postures of the workpiece, such as rotation and tilting. The rotary C-type support clamping actuator 5 is a C-shaped clamping device that can rotate and apply pressure to the overlapping area of ​​the workpiece to eliminate or control gaps. The ground rail transfer mechanism 1 is a device that runs along a ground rail and is used to automatically transport workpieces between different workstations. The side door conformal fixture 9 is a clamp customized according to the specific geometry of the loader's side door, used to precisely fix and support the workpiece. The main control cabinet 6 is an electrical control cabinet that integrates core control hardware such as a programmable logic controller (PLC) and a robot controller to achieve automated system operation.

[0035] The robot module in this embodiment primarily functions to automate the processing and welding of workpieces. This module may include at least one industrial robot, such as a welding robot 4 for performing welding tasks and a handling robot 2 for transporting workpieces. The welding robot 4 may be equipped with general-purpose welding tools, such as an arc welding torch or a laser processing head, to complete the workpiece joining operation. The handling robot 2 may be equipped with general-purpose gripping tools, such as pneumatic or electric grippers, to automatically grasp and place workpieces during loading, unloading, and transfer between workstations. This division of labor and cooperation reduces manual intervention and improves the automation level of the production line.

[0036] The positioning module is used to adjust the workpiece's posture in space to meet welding requirements. This module can be implemented using a three-axis positioner 3, for example, a three-axis positioner 3 with rotation and tilting functions. The three-axis positioner 3 clamps the workpiece through its mechanical structure and adjusts the workpiece to different angles and positions according to a preset program or operating instructions. This allows the weld to be positioned in an easily weldable posture, such as a flat welding position, thus facilitating the welding operation.

[0037] The clamping module is used to eliminate gaps caused by workpiece incoming tolerances or positioning errors. This module may include a rotary C-shaped support clamping actuator 5. This actuator can be designed as a C-shaped structure, with one end fixed and the other end movably extending outwards as a pressure head. Driven by a mechanism, such as a pneumatic or hydraulic cylinder, the pressure head applies pressure to the overlapping area of ​​the workpiece. The downward pressing action of the pressure head allows the inner and outer plates 8 of the workpiece to fit tightly together, thereby reducing or eliminating the overlapping gap. This actuator can move along a preset path to sequentially clamp multiple welding areas, ensuring gap control throughout the welding process.

[0038] The tooling module is used for the automatic transfer, precise positioning, and clamping of workpieces. This module may include a ground rail transfer mechanism 1 and a side door conformal tooling 9. The ground rail transfer mechanism 1 consists of a rail and a carrier running on the rail, with a workpiece carrying platform mounted on the carrier. This mechanism is driven by a motor, causing the carrier to reciprocate between the loading / unloading station and the welding station, achieving automatic workpiece transfer. The side door conformal tooling 9 can be customized according to the specific shape of the loader's side door and is equipped with multiple clamps, such as pneumatic or manual clamps. These clamps can clamp the workpiece after it is placed in position to ensure the positional accuracy and stability of the workpiece during the welding process. Multiple sets of the side door conformal tooling 9 are provided.

[0039] The central control module, as the core of the entire system, is responsible for the centralized control and coordination of all modules. This module can be implemented as a main control cabinet 6, which integrates a programmable logic controller (PLC) and / or an industrial computer. All execution units, including the welding robot 4, the handling robot 2, the three-axis positioner 3, the rotary C-type support clamping actuator 5, the ground rail transfer mechanism 1, and the side door conformal tooling 9, are connected to the main control cabinet 6 via signal lines. The main control cabinet 6 receives instructions from the operating interface and, according to the preset program logic, sends control signals, such as motion commands and switching commands, to each execution unit. This enables the automated and sequential operation of the entire welding process.

[0040] The laser wire-filling welding system in this embodiment automates the welding operation of loader side doors by integrating a robot module, a positioning module, a clamping module, a tooling module, and a central control module. This system effectively solves the problems of low production efficiency, large welding deformation, unstable weld quality, and low automation in traditional welding methods. Through the coordinated operation of each module, automatic workpiece transfer, precise posture adjustment, lap gap control, and automated welding can be achieved, thereby improving welding quality, reducing manual intervention, and increasing overall production efficiency.

[0041] In some embodiments, for example Figure 1 and Figure 2 As shown, welding robot 4 is a six-axis welding robot, and handling robot 2 is a six-axis handling robot.

[0042] Among them, a six-axis welding robot refers to an industrial robot with six degrees of freedom (joints). Its design allows its end effector to achieve precise adjustment of any position and orientation in three-dimensional space. This multi-joint structure gives the robot high flexibility and range of motion, enabling it to adapt to complex three-dimensional curved surface welds and ensuring that the laser welding head 5-1 is always at the optimal welding angle during the welding process. Similarly, a six-axis handling robot also refers to an industrial robot with six degrees of freedom (joints). Its main function is to achieve precise gripping, movement, and placement of workpieces. Its multi-joint design allows it to flexibly handle workpieces of different shapes and sizes and can efficiently collaborate with other automated equipment such as three-axis positioners 3.

[0043] By configuring both welding robot 4 and handling robot 2 as six-axis robots through the above technical solution, the flexibility, precision, and automation level of the entire laser wire-filling welding system are significantly improved. Specifically, the six-axis welding robot, with its six degrees of freedom, enables the laser welding head 5-1 to achieve precise posture adjustment and trajectory tracking on complex three-dimensional curved weld seams, ensuring that the optimal welding angle is maintained throughout the welding process. This effectively avoids welding defects caused by insufficient posture adjustment and significantly improves the forming quality and consistency of the weld seam. At the same time, the six-axis handling robot provides a high degree of freedom in gripping and placing, enabling it to accurately grip the workpiece from the loading station of the ground rail transfer mechanism 1 and place it into the conformal tooling on the three-axis positioner 3, and remove the finished workpiece from the tooling, effectively reducing workpiece positioning errors and improving the efficiency and accuracy of loading and unloading. This collaborative configuration of dual six-axis robots allows the system to handle workpieces with complex geometric features, such as loader side doors, more efficiently, solving problems such as unsatisfactory welding angles and inaccurate positioning caused by insufficient robot degrees of freedom, thereby improving overall production efficiency and product quality.

[0044] In some embodiments, for example Figure 3 As shown, the welding robot 4 is equipped with a laser welding head 5-1 and a weld seam recognition and tracking system 5-2 at its end. The weld seam recognition and tracking system 5-2 is used to accurately locate the weld seam.

[0045] Specifically, the six-axis welding robot 4, as the core actuator of the automated welding system, is responsible for carrying the welding tools along a preset path or a real-time tracking path to complete the welding operation on the workpiece. Its high-precision motion capability is the foundation for automated welding, ensuring the accuracy of the welding trajectory. The laser welding head 5-1 is an actuator installed at the end of the welding robot 4, used to generate and focus a high-energy laser beam to melt the workpiece material and form a weld. The laser welding head 5-1 typically integrates an optical system, a protective gas nozzle, and possibly optical sensors. Its implementation can include a fiber laser welding head 5-1, a CO2 laser welding head 5-1, or a semiconductor laser welding head 5-1, etc., capable of providing high energy density, low heat input, and high welding speed. The weld seam recognition and tracking system 5-2 is a device for real-time detection and tracking of the weld seam position. This system typically acquires geometric information or physical characteristics of the weld seam area through sensors and feeds this information back to the robot control system, enabling the welding robot 4 to dynamically adjust its motion trajectory to precisely align with the weld seam. The implementation methods can include laser vision tracking systems, CCD vision tracking systems, infrared sensor systems, or laser scanners. These systems can identify the edges, gaps, or feature points of the weld, thereby achieving precise positioning of the weld.

[0046] Through the above technical solution, when the welding robot 4 performs welding operations, the laser welding head 5-1 installed at its end provides high-precision welding energy, while the weld seam recognition and tracking system 5-2 can obtain the actual position information of the weld seam in real time and accurately. By precisely positioning the weld seam, this system can effectively compensate for weld seam position deviations caused by factors such as workpiece material tolerances, assembly errors, or thermal deformation, ensuring that the laser welding head 5-1 always welds along the correct weld seam path. This significantly improves the accuracy and consistency of welding, avoids welding defects caused by inaccurate positioning, thereby guaranteeing the weld seam's forming quality and mechanical properties, and reducing subsequent manual repair and grinding work.

[0047] In some embodiments, the rotary C-type support clamping actuator 5 integrates a pressure sensor and a displacement sensor; the pressure sensor is used to monitor the pressure value of the pressure head of the rotary C-type support clamping actuator 5 in real time; the displacement sensor is used to monitor the displacement of the rotary C-type support clamping actuator 5 in real time.

[0048] Through the above technical solution, a pressure sensor and a displacement sensor are integrated into the rotary C-type support clamping actuator 5, enabling the system to acquire the pressure value and displacement of the clamping head in real time during the clamping process. The pressure sensor monitors the pressure value of the clamping head in real time, ensuring that the clamping force can accurately reach the preset threshold, thereby applying an appropriate clamping force to the workpiece and effectively eliminating gaps caused by incoming material tolerances or positioning errors. At the same time, the displacement sensor monitors the displacement of the clamping head in real time, allowing the system to accurately grasp the relative position of the clamping head and the workpiece, thereby stabilizing the gap within the precise range required for laser wire filler welding. This real-time monitoring and feedback mechanism for the clamping process achieves closed-loop management of gap control, significantly improving the accuracy and reliability of gap control, effectively avoiding welding defects caused by improper gap control, and thus ensuring the consistency and stability of welding quality.

[0049] The present invention also proposes an operation method for a laser wire-filling welding system for automated welding of loader side doors, which is applied to the laser wire-filling welding system for automated welding of loader side doors as described in any of the above embodiments, and includes the following steps: S1, manual pre-positioning and feeding; S2, automatic transfer and feeding; S3, workpiece positioning and weld preparation; S4, weld identification and welding; S5, unloading and post-processing.

[0050] The process includes the following steps: Step S1, manual pre-positioning and loading, refers to the operator performing preliminary assembly, calibration, or pre-processing of the workpiece according to preset process requirements, and placing it in the designated loading area. Step S2, automatic transfer and loading, refers to the automated equipment precisely transferring the workpiece from the loading station to the welding station according to control commands, and completing the automatic loading. Step S3, workpiece positioning and weld preparation, refers to adjusting the spatial posture of the workpiece through a workpiece positioning device to place its welding area in the optimal welding position, while using a clamping mechanism to pre-press the weld area to control or eliminate gaps. Step S4, weld identification and welding, refers to using a weld tracking system to detect and correct the actual weld position in real time, guiding the welding robot 4 to perform laser wire filling welding along a precise path, and adjusting welding parameters according to process requirements. Step S5, unloading and post-processing, refers to the automated handling equipment removing the welded workpiece from the tooling and transferring it to the unloading station or post-processing station, while simultaneously performing preliminary quality checks.

[0051] This application provides a method for operating a laser wire-filling welding system for automated welding of loader side doors. By defining an ordered sequence of steps, it ensures the coordinated operation of all modules of the welding system, effectively solving the coordination and efficiency problems in automated execution, and significantly improving welding quality and consistency. This method makes the entire welding process highly efficient, precise, and automated, significantly improving production efficiency and product quality, reducing reliance on manual operation skills, and effectively controlling welding deformation.

[0052] In some embodiments, step S1 specifically includes the following steps: S11, the operator separates the inner and outer plates 8 that are fastened together, welds small parts and nuts on the inner plate 7, then fastens the inner and outer plates 8 together and performs preliminary positioning welding at multiple points; S12, the workpiece that has been preliminarily positioned is placed on the loading station of the ground rail transfer mechanism 1.

[0053] Specifically, in step S11, the operator first separates the workpiece to be assembled, i.e., the inner and outer panels 8 that are fastened together. This operation aims to provide the necessary operating space and convenience for subsequent welding of small parts and nuts on the inner panel 7, ensuring the accurate installation of internal components. Subsequently, small parts and nuts are welded onto the inner panel 7. These small parts and nuts can be reinforcing ribs, mounting brackets, wire harness fixing seats, or connectors for subsequent assembly. After completing the welding on the inner panel 7, the operator re-fastens the inner and outer panels 8 to form the overall structure of the side door workpiece to be welded, and performs preliminary locating welding at multiple points. This preliminary locating welding aims to initially fix the fastened workpiece by welding at multiple discrete points in the overlapping area of ​​the inner and outer panels 8. Preliminary locating welding can effectively limit the relative displacement between the inner and outer panels 8, reducing gaps and misalignments caused by incoming material tolerances or manual operation. The locating welding method can include resistance spot welding, MIG / MAG spot welding, or laser spot welding. The number and position can be set according to the size, shape, and structural stability requirements of the workpiece, for example, 4-6 points.

[0054] After the initial fixing is completed, in step S12, the pre-positioned workpiece is placed on the loading station of the ground rail transfer mechanism 1. The workpiece here refers to the semi-finished product whose inner and outer plates 8 have been pre-fitted and fixed by tack welding after processing in step S11. Its structure is relatively stable and not prone to large deformation or displacement during handling. This operation accurately places the workpiece, which has undergone preliminary manual processing, at the entrance of the automated system, i.e., the designated loading position of the ground rail transfer mechanism 1. The placement can be done manually by the operator or assisted by automated equipment such as auxiliary robotic arms or suction cups to ensure that the workpiece can be accurately identified by the ground rail transfer mechanism 1 and transferred to the subsequent automated welding station.

[0055] Using the above technical solution, before the automated welding operation begins, the operator first separates the inner and outer plates 8 of the workpiece so that small parts and nuts can be pre-welded onto the inner plate 7, ensuring the accurate installation of internal components. Subsequently, the inner and outer plates 8 are re-fastened and secured using preliminary tack welding at multiple points. This pre-treatment method effectively controls the overlap gap between the inner and outer plates 8 within a small range and significantly reduces misalignment that may be caused by incoming material tolerances or manual operation, providing a structurally stable and precisely positioned workpiece for subsequent automated welding.

[0056] Furthermore, the pre-positioned workpiece is placed on the loading station of the ground rail transfer mechanism 1, achieving seamless integration between manual operation and the automated system. This ensures that the workpiece can be accurately grasped and transferred by the automated system, avoiding secondary positioning errors that may occur during transfer. Overall, these steps work together to significantly improve the positioning accuracy and stability of the workpiece before entering the automated welding system, thus providing high-quality starting conditions for subsequent laser wire-filled welding. This effectively guarantees the final weld formation quality and consistency, reduces the difficulty of gap control during automated welding, and decreases the workload of post-weld repair and grinding.

[0057] In some embodiments, step S2 specifically includes the following steps: S21, the ground rail transfer mechanism 1 transfers the workpiece to the robot loading position; S22, the handling robot 2 grabs the workpiece and places it in the conformal tooling on the three-axis positioner 3, and the pneumatic clamp of the conformal tooling automatically clamps it.

[0058] Through the above technical solution, the ground rail transfer mechanism 1 can accurately and stably transfer the workpiece from the loading station to the robot loading station, providing a standardized gripping point for the handling robot 2. The handling robot 2 can then accurately grip the workpiece according to a preset program and place it into the conformal fixture on the three-axis positioner 3. The pneumatic clamps of the conformal fixture then automatically clamp the workpiece, ensuring precise positioning and secure fixation before welding. This effectively solves the positioning deviation problem that may occur during automated transfer and loading of workpieces, avoids welding defects caused by manual operation or inaccurate positioning, significantly improves the automation level and welding accuracy of the entire system, and lays a solid foundation for subsequent high-quality welding operations.

[0059] In some embodiments, step S3 specifically includes the following steps: S31, the three-axis positioner 3 rotates and tilts according to a preset program to adjust the workpiece to a preset welding posture, and at the same time, the rotary C-type support clamping actuator 5 moves to the first welding point position; S32, the pressure head of the rotary C-type support clamping actuator 5 presses down, and during the pressing process, the pressure sensor monitors in real time, and stops when the pressure value reaches a preset threshold, thus completing the control of the gap.

[0060] Through the above technical solution, the triaxial positioner 3 adjusts the workpiece to the optimal welding posture, laying the foundation for subsequent precise clamping and welding. The rotary C-shaped support clamping actuator 5 moves precisely to the position of the first weld point, ensuring the accuracy of clamping. The downward pressure of the pressure head, combined with real-time monitoring by a pressure sensor, achieves closed-loop control of the clamping force. When the pressure reaches a preset threshold, it stops, dynamically and accurately eliminating lap gaps caused by incoming material tolerances or positioning errors, and stably controlling them within the range required by the process. This precise gap control significantly improves the stability of welding quality, reduces welding defects, and lowers the need for subsequent grinding and repair. In conjunction with the laser wire filler welding system, it provides stable gap conditions for laser wire filler welding, further ensuring the quality and efficiency of high-energy beam welding.

[0061] In some embodiments, step S4 specifically includes the following steps: S41, the welding robot 4 drives the laser welding head 5-1 to move above the workpiece, and the weld seam recognition and tracking system 5-2 is activated to accurately locate the weld seam; S42, the welding robot 4 performs laser filler wire welding according to a predetermined trajectory; during the welding process, the three-axis positioner 3 and the welding robot 4 move in coordination to maintain the welding angle; the rotating C-type support clamping actuator 5 moves sequentially to the next weld point position to clamp according to the welding sequence.

[0062] Through the above technical solution, the welding robot 4 can move the laser welding head 5-1 above the workpiece, and the weld seam recognition and tracking system 5-2 is activated to accurately position the weld seam. Subsequently, the welding robot 4 performs laser wire filling welding according to a predetermined trajectory. During the welding process, the three-axis positioner 3 and the welding robot 4 move in coordination to maintain the welding angle, while the rotating C-shaped support clamping actuator 5 moves sequentially to the next weld point position for clamping according to the welding sequence. In addition, an infrared sensor or CCD vision tracking system can be used to identify the weld seam in real time and feed the deviation information back to the robot controller, enabling it to dynamically adjust the welding trajectory and posture to ensure welding quality and accuracy. This step is the core of achieving high-quality automated welding. Through precise control and collaborative operation, the forming quality and consistency of the weld seam are guaranteed.

[0063] In some embodiments, step S5 specifically includes the following steps: S51, after all welds are completed, the three-axis positioner 3 is reset and the tooling fixture is released; S52, the handling robot 2 removes the finished workpiece and places it at the unloading station of the ground rail transfer mechanism 1; S53, the ground rail transfer mechanism 1 moves the workpiece out and performs a final inspection by a person, including minor welding repairs and / or light grinding.

[0064] In step S51, resetting the three-axis positioner 3 refers to restoring the workpiece from a specific posture adjusted during the welding process to its initial position or a preset posture that facilitates unloading. This can be achieved by controlling the three-axis positioner 3 to move along a reverse trajectory or directly return to its zero position through preset program instructions.

[0065] In step S52, the handling robot 2 is responsible for removing the welded workpiece from the conformal tooling on the three-axis positioner 3 and transferring it to the unloading station of the ground rail transfer mechanism 1. The handling robot 2 can use a suction cup end effector to grasp the workpiece by vacuum adsorption, or a gripper end effector to grasp the workpiece by mechanical clamping.

[0066] In step S53, the ground rail transfer mechanism 1 moves the workpiece from the unloading station, typically to the manual inspection station. The ground rail transfer mechanism 1 can drive the carrier along the track via a drive motor, or smoothly transport the workpiece out of the automated area via a chain or belt drive system. Subsequently, a manual inspection of the workpiece is performed to assess the welding quality and ensure the product meets standards. The inspection mainly includes visual inspection of the weld appearance, dimensional accuracy, and presence of defects, or sampling inspection using simple measuring tools. For minor defects found during inspection, small-scale repair welding can be performed, such as using manual MAG welding or TIG welding to repair localized incomplete penetration or porosity; or light grinding can be performed, such as using handheld electric or pneumatic grinding tools to remove weld slag, spatter, or minor surface unevenness.

[0067] Through the above technical solution, after all weld seams are completed, the three-axis positioner 3 resets and the tooling fixtures are released, ensuring the safe release of the workpiece and avoiding accidental damage, providing a stable starting point for subsequent unloading operations. Next, the handling robot 2 automatically removes the finished workpiece and places it at the unloading station of the ground rail transfer mechanism 1. Robotic automation replaces manual handling, significantly reducing time waste and human error, and improving the efficiency and accuracy of the unloading process. Finally, after the ground rail transfer mechanism 1 removes the workpiece, manual inspection and necessary minor welding and / or light grinding are required, minimizing manual intervention and maintaining the continuity of automated production. This effectively solves the problems of automated process interruption and manual dependence, optimizes production cycle time, improves the efficiency and consistency of the overall welding system, and reduces the labor intensity of workers. Each feature works synergistically to achieve a seamless connection from welding completion to workpiece removal, strengthening the integrity and reliability of the system.

[0068] Other configurations and operations of the laser wire-filling welding system and method for automated welding of loader side doors according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here.

[0069] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0070] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A laser wire-filling welding system for automated welding operations on loader side doors, characterized in that, include: Robot module, positioning module, clamping module, tooling module, and central control module; The robot module includes a welding robot and a handling robot; The displacement module is a three-axis positioner, which is used to clamp and adjust the posture of the workpiece in space; The clamping module includes a rotary C-shaped support clamping actuator, which is used to eliminate gaps caused by incoming material tolerances or positioning errors. The tooling module includes a ground rail transfer mechanism and a side door conformal tooling. The ground rail transfer mechanism is used to automatically transfer workpieces between the loading / unloading station and the welding station, and the side door conformal tooling is used to accurately position and clamp the workpieces. The central control module is the main control cabinet, and the welding robot, the handling robot, the three-axis positioner, the rotary C-shaped support clamping actuator, the ground rail transfer mechanism, and the side door conformal tooling are all connected to the main control cabinet via signal.

2. The laser wire-filling welding system for automated welding operations of loader side doors according to claim 1, characterized in that, The welding robot is a six-axis welding robot, and the handling robot is a six-axis handling robot.

3. The laser wire-filling welding system for automated welding operations of loader side doors according to claim 2, characterized in that, The welding robot is equipped with a laser welding head and a weld seam recognition and tracking system at its end, which is used to accurately locate the weld seam.

4. The laser wire-filling welding system for automated welding operations of loader side doors according to claim 1, characterized in that, The rotary C-type support clamping actuator integrates a pressure sensor and a displacement sensor; The pressure sensor is used to monitor the pressure value of the pressure head of the rotary C-type support clamping actuator in real time; The displacement sensor is used to monitor the displacement of the rotary C-shaped support clamping actuator in real time.

5. A method for operating a laser wire-filling welding system for automated welding of loader side doors, applied to the laser wire-filling welding system for automated welding of loader side doors as described in any one of claims 1-4, characterized in that, Includes the following steps: S1. Manual pre-positioning and material loading; S2. Automatic transplanting and feeding; S3. Workpiece positioning and weld preparation; S4. Weld identification and welding; S5. Material preparation and post-processing.

6. The operating method of the laser wire-filling welding system for automated welding of loader side doors according to claim 5, characterized in that, Step S1 specifically includes the following steps: S11. The operator separates the inner and outer plates that are fastened together, welds small parts and nuts onto the inner plate, then fastens the inner and outer plates together and performs preliminary tack welding at multiple points. S12. Place the pre-positioned workpiece on the loading station of the ground rail transfer mechanism.

7. The operating method of the laser wire-filling welding system for automated welding of loader side doors according to claim 5, characterized in that, Step S2 specifically includes the following steps: S21, The ground rail transfer mechanism transfers the workpiece to the robot's loading position; S22. The handling robot grabs the workpiece and places it in the conformal tooling on the three-axis positioner. The pneumatic clamp of the conformal tooling automatically clamps it.

8. The operating method of the laser wire-filling welding system for automated welding of loader side doors according to claim 5, characterized in that, Step S3 specifically includes the following steps: S31, the three-axis positioner rotates and tilts according to the preset program to adjust the workpiece to the preset welding posture. At the same time, the rotating C-type support clamping actuator moves to the position of the first welding point. S32. The pressure head of the rotating C-type support clamping actuator presses down. During the pressing process, the pressure sensor monitors in real time. When the pressure value reaches the preset threshold, it stops, thus completing the control of the gap.

9. The operating method of the laser wire-filling welding system for automated welding of loader side doors according to claim 5, characterized in that, Step S4 specifically includes the following steps: S41. The welding robot moves the laser welding head above the workpiece, and the weld seam recognition and tracking system is activated to accurately locate the weld seam. S42. The welding robot performs laser wire filling welding according to a predetermined trajectory. During the welding process, the three-axis positioner moves in coordination with the welding robot to maintain the welding angle. The rotating C-shaped support clamping actuator moves to the next weld point position for clamping according to the welding sequence.

10. The operating method of the laser wire-filling welding system for automated welding of loader side doors according to claim 5, characterized in that, Step S5 specifically includes the following steps: S51. After all welds are completed, the triaxial positioner is reset and the tooling fixtures are released. S52. The handling robot removes the finished workpiece and places it at the unloading station of the ground rail transfer mechanism; S53. The ground rail transfer mechanism removes the workpiece, and a final inspection is carried out manually. The inspection includes minor welding repairs and / or light grinding.

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