Automatic welding equipment for transformer copper shielding piece

Abstract

The embodiment of the invention discloses automatic welding equipment for a transformer copper shielding piece, a welding platform is located between a wire feeder and a welding mechanical arm, the welding platform is used for bearing an oil tank wall steel plate and the copper shielding piece to be welded, the copper shielding piece is placed on the oil tank wall steel plate, and the copper shielding piece is provided with a plurality of positions to be welded. And the scanner faces the welding platform, is electrically connected with the control unit and is used for sending image data of the copper shielding piece and the oil tank wall steel plate to the control unit. And the control unit is electrically connected with the welding mechanical arm and the wire feeder, and is used for identifying the welding seam type of each to-be-welded position according to the received image data, controlling the wire feeder to feed wires according to the welding seam type, and controlling the welding mechanical arm to weld according to a preset welding path. The equipment can realize automatic welding of the copper shielding piece.

Description

Technical Field

[0001] This invention specifically relates to an automated welding device for copper shielding components of transformers. Background Technology

[0002] With the rapid development of my country's economy and power industry, the demand for high-voltage, large-capacity power transformers is increasing daily. During transformer manufacturing, to prevent leakage flux from entering the tank wall and causing localized overheating and additional losses, copper shielding components need to be welded onto the tank wall. The welding quality of the copper shielding components directly determines the performance and reliability of the transformer.

[0003] The welding process of copper shielding components is mostly done manually. However, manual welding is inefficient and prone to problems such as discontinuous welds and missed welds.

[0004] Currently, automated welding equipment has emerged to improve welding efficiency. However, existing automated welding equipment is only suitable for simple weld seams, while the weld seams of copper shielding components are complex, so existing welding equipment cannot yet achieve automated welding of copper shielding components. Summary of the Invention

[0005] The technical problem to be solved by the embodiments of the present invention is to address the above-mentioned deficiencies in the prior art by providing an automated welding equipment for copper shielding components of transformers, which can realize automated welding of copper shielding components.

[0006] In an embodiment of the present invention, an automated welding device for a transformer copper shield is provided, comprising: a welding platform, a wire feeder, a welding robotic arm, a scanner, and a control unit. The welding platform is located between the wire feeder and the welding robotic arm, and is used to support a tank wall steel plate and the copper shield to be welded. The copper shield is placed on the tank wall steel plate and has multiple welding positions. The scanner faces the welding platform and is electrically connected to the control unit. The scanner is used to send image data of the copper shield and the tank wall steel plate to the control unit. The control unit is electrically connected to the welding robotic arm and the wire feeder, and is used to identify the weld type of each welding position based on the received image data, and control the wire feeder to feed wire according to the weld type, and control the welding robotic arm to weld according to a preset welding path.

[0007] The welding equipment in this embodiment of the invention obtains image data of the copper shielding component and the steel plate of the fuel tank wall through a scanner. The control unit, based on the received image data, can identify the weld type of each position to be welded. Furthermore, the control unit, based on the weld type of each position, controls the wire feeder to feed wire and controls the welding robotic arm to weld according to a preset welding path. Further, existing automatic welding equipment can only perform single-type, simple weld welding, while the copper shielding component has multiple positions to be welded, and each position corresponds to a different weld type. Different weld types require different welding paths and different wire feeding speeds. Therefore, existing automatic welding equipment cannot weld objects like copper shielding components. This welding equipment, by identifying the weld type of each position to be welded, can complete the welding operation of each position of the copper shielding component by referring to a preset welding path, thereby enabling the welding of the copper shielding component.

[0008] In summary, the automated welding equipment for the copper shielding of this transformer can achieve automated welding of the copper shielding.

[0009] Optionally, the control unit includes a first processor and a second processor; the first processor is electrically connected to the scanner and the second processor, and is used to output a characteristic voltage signal of the weld to the second processor based on the image data emitted by the scanner; the second processor is electrically connected to the wire feeder and the welding robot arm respectively, and is used to determine the weld type of the position to be welded based on the characteristic voltage signal, and send a wire feeding control signal to the wire feeder and a welding path control signal to the welding robot arm based on the weld type; the wire feeder is used to feed wire according to the received wire feeding control signal; the welding robot arm is used to perform welding according to the welding path set by the received welding path control signal.

[0010] Optionally, the control unit further includes: a memory; the memory pre-stores welding path parameters corresponding to various weld types; the second processor includes a feature matching circuit and a signal generation circuit; the feature matching circuit is electrically connected to the first processor and the signal generation circuit, and is used to determine the weld type of the position to be welded based on the feature voltage signal emitted by the first processor, and to send a weld type signal to the signal generation circuit; the signal generation circuit is electrically connected to the memory, the wire feeder and the welding robot arm, and is used to call the corresponding welding path parameters in the memory based on the weld type signal, and to generate a wire feeding control signal and a welding path control signal.

[0011] Optionally, the weld types include: butt welds, fillet welds, and round hole plug welds; the memory pre-stores welding path parameters corresponding to butt welds, fillet welds, and round hole plug welds.

[0012] Optionally, the feature matching circuit includes: a comparator array and a priority encoder; the comparator array includes multiple comparators connected in parallel, each comparator having a first input terminal, a second input terminal, and an output terminal; the first input terminals of the comparators are all electrically connected to the first processor and are used to receive the feature voltage signal; the second input terminals of the comparators are used to receive reference voltage signals corresponding to different weld types issued by the digital-to-analog converter; the output terminals of the comparators are all electrically connected to the input terminals of the priority encoder.

[0013] Optionally, the comparator array includes a first comparator, a second comparator, and a third comparator, all of which are connected in parallel. The first input terminals of each of the first, second, and third comparators are electrically connected to the first processor to receive the characteristic voltage signal. The second input terminal of the first comparator receives a first reference voltage signal from the digital-to-analog converter (DAC). The second input terminal of the second comparator receives a second reference voltage signal from the DAC. The second input terminal of the third comparator receives a third reference voltage signal from the DAC. The outputs of both the second and third comparators are electrically connected to the priority encoder. The first comparator outputs a first high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the first reference voltage signal, and outputs a first low-level signal otherwise. The second comparator outputs a second high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the second reference voltage signal, and outputs a second low-level signal otherwise. The third comparator outputs a third high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the third reference voltage signal, and outputs a third low-level signal otherwise.

[0014] Optionally, the priority encoder is electrically connected to the signal generation circuit and is used to output a first control signal to the signal generation circuit when a first high-level signal is received; or, to output a second control signal to the signal generation circuit when a first low-level signal and a second high-level signal are received; or, to output a third control signal to the signal generation circuit when a first low-level signal, a second low-level signal, and a third high-level signal are received.

[0015] Optionally, the signal generation circuit is configured to, upon receiving a first control signal, call the welding path parameters corresponding to the fillet weld in the memory to generate a first wire feed control signal and a first welding path control signal; or, upon receiving a second control signal, call the welding path parameters corresponding to the butt weld in the memory to generate a second wire feed control signal and a second welding path control signal; or, upon receiving a third control signal, call the welding path parameters corresponding to the round hole plug weld in the memory to generate a third wire feed control signal and a third welding path control signal.

[0016] Optionally, the wire feeder includes a housing, a wire spool support, and a wire feeding drive unit. The wire spool support is installed inside the housing and is used to support the wire spool. The wire spool can rotate around its central axis to release the welding wire. The wire feeding drive unit includes a drive motor, a drive wheel, a pressure wheel, and a wire outlet nozzle. The wire outlet end of the wire spool faces the wire outlet nozzle. The drive wheel and the pressure wheel are located between the wire spool and the wire outlet nozzle, and are arranged vertically opposite each other. The circumferential surface of the clamping wheel presses against the circumferential surface of the driving wheel; the welding wire passes through the wire outlet end, between the clamping wheel and the driving wheel, and the wire outlet nozzle; the clamping wheel and the driving wheel cooperate to clamp the welding wire; the output end of the drive motor is connected to the driving wheel to drive the driving wheel to rotate, thereby driving the welding wire to be fed out from the wire outlet nozzle; the control unit is electrically connected to the drive motor to control the rotation speed of the drive unit according to the weld type, thereby controlling the wire feeding speed.

[0017] Optionally, the welding robotic arm includes: a robotic arm body and a welding torch; the welding torch is installed at the end of the robotic arm body, the control unit is electrically connected to the robotic arm body, and is used to control the robotic arm body to drive the welding torch to move along the welding path, the wire outlet is connected to the welding torch through a flexible wire guide tube, and the welding wire is fed to the conductive tip of the welding torch through the flexible wire guide tube, thereby placing the welding wire at the position to be welded to achieve welding. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the automated welding equipment for the transformer copper shielding component in an embodiment of the present invention; Figure 2 This is a schematic diagram of the operation of the automated welding equipment for the transformer copper shield in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of the copper shielding component to be soldered in an embodiment of the present invention.

[0019] In the diagram: 1. Wire feeder; 2. Welding robotic arm; 3. Scanner; 4. Control unit; 5. Copper shielding; 51. Fillet weld; 52. Butt weld; 53. Circular hole plug weld; 6. Tank wall steel plate; 7. Welding wire. Detailed Implementation

[0020] The technical solutions of the invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without creative effort are within the scope of the invention.

[0021] In the description of this invention, it should be noted that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience and simplification of the description and do not indicate or imply that the device or element referred to 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.

[0022] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connection," "setting," "installation," "fixing," etc., 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 or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0024] To facilitate understanding of the embodiments of the present invention, the application scenarios of the present invention will be further explained first.

[0025] With the rapid development of my country's economy and power industry, the demand for power transformers is increasing. In the manufacturing process of transformer tanks, copper shielding welding is a crucial step, and its quality significantly impacts the transformer's quality and performance. To prevent leakage flux from entering the transformer tank wall, copper shielding needs to be welded to the tank wall. If the copper shielding welding is inadequate, it often fails to reduce transformer leakage flux, threatening the safe operation of the transformer. Therefore, it is necessary to develop a device that can automatically weld transformer copper shielding, changing the previous manual welding method. This improves the efficiency and safety of transformer copper shielding welding, and is highly significant for reducing transformer leakage flux and improving transformer quality.

[0026] However, existing automated equipment is not suitable for automated welding of copper shielding components.

[0027] To address this issue, this invention proposes a device that can effectively match the welding shape of copper shielding, preventing unsatisfactory welding results caused by errors in manual welding. The development of this equipment enables automated welding of copper shielding components, significantly reducing the probability of increased transformer leakage flux due to errors, thus ensuring the safety and quality of the transformer during use.

[0028] Example 1

[0029] Please see Figure 1 and Figure 2 This invention discloses an automated welding equipment for a transformer copper shield, comprising: a welding platform, a wire feeder 1, a welding robotic arm 2, a scanner 3, and a control unit 4.

[0030] The welding platform is located between the wire feeder 1 and the welding robotic arm 2. The welding platform supports the tank wall steel plate 6 and the copper shielding component 5 to be welded. The copper shielding component 5 is placed on the tank wall steel plate 6 and has multiple welding positions. A scanner 3, facing the welding platform, is electrically connected to a control unit 4. The scanner 3 sends image data of the copper shielding component 5 and the tank wall steel plate 6 to the control unit 4. The control unit 4, electrically connected to the welding robotic arm 2 and the wire feeder 1, identifies the weld type of each welding position based on the received image data, controls the wire feeder 1 to feed wire according to the weld type, and controls the welding robotic arm 2 to weld according to a preset welding path.

[0031] It should be noted that, as Figure 3 As shown, the weld types of the copper shielding component 5 include: butt weld 52, fillet weld 51, and plug weld 53. In other words, there are three connection methods (welding methods) between the copper shielding and the tank: butt weld 52, fillet weld 51, and plug weld, with different connection methods corresponding to different weld shapes. Since the copper plate size of the copper shielding is generally 1m... The transformer tank's copper shield (component) is 2m long, therefore, it is composed of multiple copper plates spliced ​​together. To ensure effective contact between the copper shield and the tank's steel plate, a certain number of plug weld holes need to be processed in the copper shield. Therefore, the connection methods between the copper shield and the tank are divided into three types: butt weld 52, fillet weld 51, and round hole plug weld 53.

[0032] Specifically, when two copper plates are joined together, a narrow linear welding area is formed between them, corresponding to a butt weld type 52. The edges of the copper plates and the corners of the surface of the tank wall steel plate 6 correspond to fillet weld type 51. The circular outline holes on the surface of the copper plates correspond to a plug weld type 53.

[0033] In this embodiment, the welding equipment obtains image data of the copper shielding component 5 and the steel plate of the tank wall 6 through the scanner 3. The control unit 4, based on the received image data, can identify the weld type at each location to be welded. Furthermore, the control unit 4, based on the weld type at each location to be welded, controls the wire feeder 1 to feed wire and controls the welding robotic arm 2 to perform welding according to a preset welding path.

[0034] Furthermore, existing automatic welding equipment can only perform single-type, simple weld seam welding, while the copper shielding component 5 has multiple welding positions, each corresponding to a different weld seam type. Different weld seam types require different welding paths and wire feed speeds. Therefore, existing automatic welding equipment cannot weld objects like the copper shielding component 5. This welding equipment, however, identifies the weld seam type of each welding position and can complete the welding operation for each welding position of the copper shielding component 5 by referring to a preset welding path, thereby enabling the welding of the copper shielding component 5.

[0035] In summary, the automated welding equipment for the copper shielding of this transformer can achieve automated welding of the copper shielding component 5.

[0036] In this embodiment, the control unit 4 includes a first processor and a second processor. The first processor, electrically connected to the scanner 3 and the second processor, is used to output a characteristic voltage signal of the weld to the second processor based on the image data emitted by the scanner 3. The second processor, electrically connected to the wire feeder 1 and the welding robotic arm 2 respectively, is used to determine the weld type at the welding position based on the characteristic voltage signal, and based on the weld type, to send a wire feeding control signal to the wire feeder 1 and a welding path control signal to the welding robotic arm 2. The wire feeder 1 is used to feed wire according to the received wire feeding control signal. The welding robotic arm 2 is used to perform welding according to the received welding path control signal.

[0037] Specifically, scanner 3 can be a commercially available laser scanner 3. The first processor can be implemented using a commercially available image processor chip.

[0038] Laser scanner 3 scans the working area (i.e., copper shield 5 and tank wall steel plate 6) to obtain three-dimensional point cloud data of the area. The three-dimensional point cloud data contains geometric feature parameters of the location to be welded.

[0039] The first processor can identify the welding positions and the connection methods (i.e., weld types) of each welding position based on geometric feature parameters. The first processor is also used to output characteristic voltage signals according to the weld type; the voltage values ​​of the characteristic voltage signals corresponding to various weld types are preset. For example, when the first processor identifies the weld type of the current welding position as a fillet weld 51, the output characteristic voltage signal has a voltage value of 15V; when the first processor identifies the weld type of the current welding position as a butt weld 52, the output characteristic voltage signal has a voltage value of 10V; and when the first processor identifies the weld type of the current welding position as a round hole plug weld 53, the output characteristic voltage signal has a voltage value of 5V.

[0040] In this embodiment, the control unit 4 further includes a memory. The memory pre-stores welding path parameters corresponding to various weld types. Specifically, the memory can be a commercially available memory chip. The memory pre-stores welding path parameters corresponding to butt welds 52, fillet welds 51, and plug welds 53.

[0041] The second processor includes a feature matching circuit and a signal generation circuit. The feature matching circuit, electrically connected to the first processor and the signal generation circuit, determines the weld type of the position to be welded based on the feature voltage signal emitted by the first processor and sends a weld type signal to the signal generation circuit. The signal generation circuit, electrically connected to the memory, wire feeder 1, and welding robotic arm 2, retrieves the corresponding welding path parameters from the memory based on the weld type signal and generates wire feeding control signals and welding path control signals.

[0042] Specifically, the feature matching circuit includes a comparator array and a priority encoder. The comparator array can be implemented using commercially available comparator chips. The priority encoder can be implemented using commercially available priority encoder chips.

[0043] The comparator array includes multiple comparators connected in parallel, each with a first input, a second input, and an output. The first input of each comparator is electrically connected to a first processor to receive a characteristic voltage signal. The second input of each comparator receives a reference voltage signal corresponding to different weld types, generated by a digital-to-analog converter. The output of each comparator is electrically connected to the input of a priority encoder.

[0044] A digital-to-analog converter (DAC) can be implemented using a commercially available DAC chip. The DAC has three output terminals, used to output preset first reference voltage signals, second reference voltage signals, and third reference voltage signals.

[0045] Furthermore, the comparator array includes a first comparator, a second comparator, and a third comparator, all connected in parallel. The first input terminals of each of the three comparators are electrically connected to the first processor to receive a characteristic voltage signal. The second input terminal of the first comparator receives a first reference voltage signal from the digital-to-analog converter (DAC). The second input terminal of the second comparator receives a second reference voltage signal from the DAC. The second input terminal of the third comparator receives a third reference voltage signal from the DAC. The output terminals of each of the three comparators are electrically connected to a priority encoder. The first comparator outputs a first high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the first reference voltage signal; otherwise, it outputs a first low-level signal. The second comparator outputs a second high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the second reference voltage signal; otherwise, it outputs a second low-level signal. The third comparator is used to output a third high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the third reference voltage signal, and otherwise output a third low-level signal.

[0046] Specifically, the comparators described above can all be commercially available comparator chips, or multiple comparators integrated into a single chip. The voltage values ​​of the reference voltage signals are preset in the digital-to-analog converter. For example, the voltage value of the first reference voltage signal is 12.5V; the voltage value of the second reference voltage signal is 7.5V; and the voltage value of the third reference voltage signal is 2.5V.

[0047] When the first processor identifies the weld type at the current welding position as a fillet weld 51, the output characteristic voltage signal has a voltage value of 15V. At this time, the voltage value of the characteristic voltage signal is greater than the voltage value of the first reference voltage signal, that is, the first comparator outputs a first high-level signal. At the same time, the second and third comparators also output high-level signals.

[0048] When the first processor identifies the weld type of the current welding position as a butt weld 52, the output characteristic voltage signal has a voltage value of 10V. At this time, the voltage value of the characteristic voltage signal is less than the voltage value of the first reference voltage signal and greater than the voltage value of the second reference voltage signal. That is, the first comparator outputs a first low-level signal, and the second comparator and the third comparator both output a second high-level signal.

[0049] When the first processor identifies the weld type of the current welding position as a round hole plug weld 53, the output characteristic voltage signal has a voltage value of 5V. At this time, the voltage value of the characteristic voltage signal is less than the voltage value of the second reference voltage signal and greater than the voltage value of the third reference voltage signal. That is, the first comparator and the second comparator output low-level signals, while the third comparator outputs a third high-level signal.

[0050] A priority encoder, electrically connected to a signal generation circuit, is used to output a first control signal to the signal generation circuit upon receiving a first high-level signal. Alternatively, it can output a second control signal to the signal generation circuit upon receiving a first low-level signal and a second high-level signal. Or, it can output a third control signal to the signal generation circuit upon receiving a first low-level signal, a second low-level signal, and a third high-level signal.

[0051] It is easy to understand that when the priority encoder receives the first high-level signal, regardless of whether the output of the second comparator and the third comparator is a high-level signal or a low-level signal, the first control signal is output, that is, the determination bit is that the weld type corresponding to the position to be welded is a fillet weld 51.

[0052] When the priority encoder receives the first low-level signal and the second high-level signal, regardless of whether the output of the third comparator is a high-level signal or a low-level signal, it outputs the second control signal, that is, it determines that the weld position corresponds to the weld type of butt weld 52.

[0053] When the priority encoder receives the first low-level signal, the second low-level signal, and the third high-level signal, it outputs the third control signal, which determines that the position to be welded corresponds to the weld type 53, which is a round hole plug weld.

[0054] In other words, the priority settings in this priority encoder are as follows: the first high-level signal has a higher priority than the second high-level signal, and the second high-level signal has a higher priority than the third high-level signal. Setting the priority of a priority encoder is a common existing technology and will not be elaborated on here.

[0055] Furthermore, the signal generation circuit is configured to, upon receiving the first control signal, retrieve the welding path parameters corresponding to the fillet weld 51 from the memory to generate a first wire feed control signal and a first welding path control signal. Alternatively, upon receiving the second control signal, retrieve the welding path parameters corresponding to the butt weld 52 from the memory to generate a second wire feed control signal and a second welding path control signal. Alternatively, upon receiving the third control signal, retrieve the welding path parameters corresponding to the round hole plug weld 53 from the memory to generate a third wire feed control signal and a third welding path control signal.

[0056] Please see Figure 1 and Figure 2 In this embodiment, the wire feeder 1 includes a housing, a wire spool support, and a wire feeding drive unit.

[0057] The welding wire 7 reel support is installed inside the machine housing. The welding wire 7 reel support supports the welding wire 7 reel, which can rotate around its central axis to release the welding wire 7. The wire feeding drive unit includes a drive motor, a drive wheel, a clamping wheel, and a wire outlet nozzle. The wire outlet end of the welding wire 7 reel faces the wire outlet nozzle. The drive wheel and clamping wheel are located between the welding wire 7 reel and the wire outlet nozzle, arranged vertically opposite each other, with the circumferential surface of the clamping wheel pressing against the circumferential surface of the drive wheel. The welding wire 7 passes through the wire outlet end, between the clamping wheel and the drive wheel, and through the wire outlet nozzle. The clamping wheel and the drive wheel cooperate to clamp the welding wire 7. The output end of the drive motor is connected to the drive wheel to drive its rotation, thereby feeding the welding wire 7 out of the wire outlet nozzle. The control unit 4 is electrically connected to the drive motor and controls the rotation speed of the drive unit according to the weld type, thereby controlling the wire feeding speed.

[0058] Specifically, the wire feeder 1 is a mature automatic wire feeding device, and commercially available wire feeding devices can be used, so it will not be described in detail here. The main optimization of the automatic welding device in this embodiment is that the type of weld seam at the position to be welded on the copper shield 5 is identified by the scanner 3 and the first and second processors, and then the wire feeding speed of the wire feeder 1 and the welding path of the welding robot arm 2 can be controlled according to the pre-stored control parameters.

[0059] The welding robotic arm 2 includes a robotic arm body and a welding torch. The robotic arm body is a six-axis robotic arm. The welding torch is mounted at the end of the robotic arm body. The control unit 4 is electrically connected to the robotic arm body and controls the robotic arm body to move the welding torch along the welding path. The wire feed nozzle is connected to the welding torch through a flexible wire guide tube. The welding wire 7 is fed to the conductive tip of the welding torch through the flexible wire guide tube, thereby guiding the welding wire 7 to the position to be welded, thus achieving welding.

[0060] Welding robotic arm 2 is already a mature automated device, and commercially available welding robotic arm 2 equipment can be used, so it will not be described in detail here.

[0061] In summary, this embodiment proposes a transformer copper shield welding robot, mainly composed of a wire feeder 1, a welding robotic arm 2, a scanner 3, and a computer. Before welding, the welding wire 7 needs to be placed next to the joint of the welding robotic arm 2 to ensure the synchronization of wire feeding and welding wire 7; at the same time, after the scanner 3 scans the copper shield and the oil tank, the corresponding welding shape needs to be set according to their different connection methods to ensure that the welding robotic arm 2 can perform copper shield welding according to the corresponding shape. When the welding is completed, the computer will issue a corresponding alarm prompt.

[0062] The copper shielding welding robot consists of a wire feeder 1, a welding robotic arm 2, a scanner 3, and a computer. The welding wire 7 from the wire feeder 1 needs to be placed at the joint of the welding robotic arm 2 to ensure simultaneous wire feeding and welding during the welding process. The scanner 3, based on laser scanning principles, is used to scan the shape of the copper shielding and the oil tank. The computer, based on the scanned shape of the copper shielding and the oil tank, can draw the shape to be welded, further ensuring the welding effect. To prevent collisions, the edges of the copper shielding welding robot are rounded.

[0063] like Figure 3 As shown, before welding, the copper shield and oil tank are scanned by scanner 3. Then, the corresponding welding shape is set according to the connection method of the copper shield and oil tank, and "Confirm" is clicked on the computer interface (if there is an error in the path setting, the "Cancel" button can be pressed to reset the welding path). The copper shield welding can then begin, and the wire feeder 1 will start working at the same time. After welding is completed, the computer will issue a corresponding alarm prompt and display "Welding Complete" on the screen.

[0064] As can be seen, this equipment, by adding a welding robot, scanner 3, and control unit 4, makes welding more intelligent. Furthermore, it can set corresponding welding shapes according to different connection methods of the copper shield and oil tank, effectively avoiding the problem of high transformer leakage flux caused by human welding errors during the welding process. This new type of equipment can save a significant amount of time and reduce manual labor intensity during the copper shield welding process of transformer oil tanks, thereby shortening the production cycle of transformer products.

[0065] This equipment effectively sets the welding shape for the copper shield and uses a welding robotic arm 2 to weld the copper shield, demonstrating the intelligence of the welding process. This reduces the probability of increased magnetic leakage due to human welding errors, ensuring the safety and quality of the transformer during operation. A scanner 3 scans the connection method between the copper shield and the tank, and based on this, sets the welding shape for the copper shield, ensuring that the welding robotic arm 2 can weld the copper shield according to the corresponding shape, demonstrating the accuracy of the welding shape. By using digital tools to set the welding shape for the copper shield of the transformer tank and performing automatic welding, welding accuracy is achieved, avoiding unsatisfactory welding results due to human error.

[0066] This equipment has the advantages of simple operation, easy installation, intelligent operation, high accuracy, and high reliability.

[0067] The following is a description of the overall working process of the automated welding equipment in this embodiment: Scanner 3 scans the copper shield 5 and the tank wall steel plate 6 to obtain image data of the copper shield 5 and the tank wall steel plate 6. Then, the first processor receives the image data from scanner 3, processes the image data, and outputs a characteristic voltage signal. The first input terminals of the first, second, and third comparators in the second processor receive the characteristic voltage signal output by the first processor. The second input terminals of the first, second, and third comparators are respectively connected to the three output terminals of the digital-to-analog converter, receiving the first reference voltage signal, the second reference voltage signal, and the third reference voltage signal, respectively.

[0068] When the characteristic voltage signal is greater than the voltage value of the first reference voltage signal, the first comparator outputs a first high-level signal; when the characteristic voltage signal is less than the voltage value of the first reference voltage signal but greater than the voltage value of the second reference voltage signal, the second comparator outputs a second high-level signal; when the characteristic voltage signal is less than the voltage value of the second reference voltage signal but greater than the voltage value of the third reference voltage signal, the third comparator outputs a third high-level signal.

[0069] The priority settings in the priority encoder are as follows: the priority of the first high-level signal is higher than that of the second high-level signal and higher than that of the third high-level signal. That is, when the priority encoder receives the first high-level signal, it outputs the first control signal first; when the priority encoder receives the first low-level signal and the second high-level signal, it outputs the second control signal; when the priority encoder receives the first low-level signal, the second low-level signal and the third high-level signal, it outputs the third control signal.

[0070] Finally, when the signal generation circuit receives the first control signal, it calls the welding path parameters corresponding to the fillet weld 51 in the memory to generate the first wire feeding control signal and the first welding path control signal; when it receives the second control signal, it calls the welding path parameters corresponding to the butt weld 52 in the memory to generate the second wire feeding control signal and the second welding path control signal; when it receives the third control signal, it calls the welding path parameters corresponding to the round hole plug weld 53 in the memory to generate the third wire feeding control signal and the third welding path control signal.

[0071] Wire feeder 1 feeds wire according to the received first / second / third wire feeding control signals to achieve different wire feeding speeds, thereby accommodating different weld types. Welding robot arm 2 performs welding according to the welding paths corresponding to the received first / second / third welding path control signals to achieve welding of different weld types.

[0072] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. An automated welding equipment for transformer copper shielding components, characterized in that, include: Welding platform, wire feeder (1), welding robotic arm (2), scanner (3) and control unit (4); The welding platform is located between the wire feeder (1) and the welding robot arm (2). The welding platform is used to support the tank wall steel plate (6) and the copper shielding component (5) to be welded. The copper shielding component (5) is placed on the tank wall steel plate (6) and has multiple welding positions. The scanner (3) faces the welding platform and is electrically connected to the control unit (4). The scanner (3) is used to send image data of the copper shield (5) and the tank wall steel plate (6) to the control unit (4). The control unit (4) is electrically connected to the welding robot arm (2) and the wire feeder (1), and is used to identify the weld type of each position to be welded according to the received image data, and control the wire feeder (1) to feed wire according to the weld type, and control the welding robot arm (2) to weld according to the preset welding path.

2. The automated welding equipment for transformer copper shielding components according to claim 1, characterized in that, The control unit (4) includes a first processor and a second processor; The first processor is electrically connected to the scanner (3) and the second processor, and is used to output a characteristic voltage signal of the weld to the second processor based on the image data emitted by the scanner (3); The second processor is electrically connected to the wire feeder (1) and the welding robot (2) respectively, and is used to determine the weld type of the position to be welded according to the characteristic voltage signal, and send a wire feeding control signal to the wire feeder (1) and a welding path control signal to the welding robot (2) according to the weld type. The wire feeder (1) is used to feed wire according to the received wire feeding control signal; The welding robotic arm (2) is used to perform welding according to the welding path set by the received welding path control signal.

3. The automated welding equipment for transformer copper shielding components according to claim 2, characterized in that, The control unit (4) further includes: a memory; The memory contains pre-stored welding path parameters corresponding to various weld types; The second processor includes a feature matching circuit and a signal generation circuit; The feature matching circuit is electrically connected to the first processor and the signal generation circuit. The feature matching circuit is used to determine the weld type of the position to be welded based on the feature voltage signal sent by the first processor, and send a weld type signal to the signal generation circuit. The signal generation circuit is electrically connected to the memory, the wire feeder (1) and the welding robot (2), and is used to call the corresponding welding path parameters in the memory according to the weld type signal, and generate wire feeding control signal and welding path control signal.

4. The automated welding equipment for transformer copper shielding components according to claim 3, characterized in that, The weld types include: butt weld (52), fillet weld (51) and round hole plug weld (53); the memory stores the welding path parameters corresponding to the butt weld (52), the welding path parameters corresponding to the fillet weld (51) and the welding path parameters corresponding to the round hole plug weld (53).

5. The automated welding equipment for transformer copper shielding components according to claim 4, characterized in that, The feature matching circuit includes: a comparator array and a priority encoder; The comparator array includes multiple comparators connected in parallel, each comparator having a first input terminal, a second input terminal, and an output terminal; The first input terminals of the comparators are all electrically connected to the first processor and are used to receive the characteristic voltage signal; The second input terminal of the comparator is used to receive reference voltage signals corresponding to different weld types issued by the digital-to-analog converter; The outputs of the comparators are all electrically connected to the inputs of the priority encoder.

6. The automated welding equipment for transformer copper shielding components according to claim 5, characterized in that, The comparator array includes a first comparator, a second comparator, and a third comparator, wherein the first comparator, the second comparator, and the third comparator are all connected in parallel. The first input terminals of the first comparator, the second comparator, and the third comparator are all electrically connected to the first processor for receiving the characteristic voltage signal. The second input terminal of the first comparator is used to receive a first reference voltage signal from the digital-to-analog converter. The second input terminal of the second comparator is used to receive the second reference voltage signal generated by the digital-to-analog converter. The second input terminal of the third comparator is used to receive the third reference voltage signal generated by the digital-to-analog converter. The outputs of the first comparator, the second comparator, and the third comparator are all electrically connected to the priority encoder. The first comparator is configured to output a first high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the first reference voltage signal, and otherwise output a first low-level signal. The second comparator is configured to output a second high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the second reference voltage signal, and otherwise output a second low-level signal. The third comparator is configured to output a third high-level signal when the voltage value of the characteristic voltage signal is greater than or equal to the voltage value of the third reference voltage signal, and otherwise output a third low-level signal.

7. The automated welding equipment for transformer copper shielding components according to claim 6, characterized in that, The priority encoder, electrically connected to the signal generation circuit, is used to output a first control signal to the signal generation circuit upon receiving a first high-level signal; or, Upon receiving a first low-level signal and a second high-level signal, a second control signal is output to the signal generation circuit; or, Upon receiving the first low-level signal, the second low-level signal, and the third high-level signal, a third control signal is output to the signal generation circuit.

8. The automated welding equipment for transformer copper shielding components according to claim 7, characterized in that, The signal generation circuit is used to, upon receiving the first control signal, call the welding path parameters corresponding to the fillet weld (51) in the memory to generate a first wire feed control signal and a first welding path control signal; or, Upon receiving the second control signal, the welding path parameters corresponding to the butt weld (52) in the memory are retrieved to generate a second wire feed control signal and a second welding path control signal; or, Upon receiving the third control signal, the welding path parameters corresponding to the circular hole plug weld (53) in the memory are called to generate the third wire feeding control signal and the third welding path control signal.

9. The automated welding equipment for transformer copper shielding components according to claim 1, characterized in that, The wire feeder (1) includes a housing, a wire (7) reel support, and a wire feeding drive unit. The welding wire (7) spool bracket is installed inside the housing. The welding wire (7) spool bracket is used to support the welding wire (7) spool. The welding wire (7) spool can rotate around its own central axis to release the welding wire (7). The wire feeding drive unit includes a drive motor, a drive wheel, a pressure wheel, and a wire outlet nozzle; The wire exit end of the welding wire (7) reel is directly opposite the wire exit nozzle; The drive wheel and the clamping wheel are located between the welding wire (7) reel and the wire outlet. The drive wheel and the clamping wheel are arranged opposite each other, and the circumferential wheel surface of the clamping wheel presses against the circumferential wheel surface of the drive wheel. The welding wire (7) is threaded between the wire outlet end, the clamping wheel and the driving wheel, and the wire outlet nozzle. The clamping wheel and the driving wheel cooperate to clamp the welding wire (7). The output end of the drive motor is connected to the drive wheel and is used to drive the drive wheel to rotate, thereby driving the welding wire (7) to be fed out from the wire outlet. The control unit (4) is electrically connected to the drive motor and is used to control the rotation speed of the drive unit according to the weld type, thereby controlling the wire feeding speed.

10. The automated welding equipment for transformer copper shielding components according to claim 9, characterized in that, The welding robotic arm (2) includes: the robotic arm body and the welding torch; The welding torch is mounted at the end of the robotic arm body. The control unit (4) is electrically connected to the robotic arm body and is used to control the robotic arm body to move the welding torch along the welding path. The wire outlet is connected to the welding gun via a flexible wire guide tube. The welding wire (7) is fed to the conductive tip of the welding gun via the flexible wire guide tube, thereby placing the welding wire (7) at the welding position to achieve welding.

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