Automatic cable trough assembling and welding system

Abstract

The invention belongs to the technical field of industrial automatic manufacturing, and particularly relates to an automatic cable trough assembling and welding system which comprises an automatic assembling station, an automatic welding station, a logistics transfer system and an integrated control system. The full-process automatic operation of the cable trough from bulk material feeding to finished product discharging is achieved, and the manual dependency degree and the labor intensity are greatly reduced. In the logistics link, cross-station transfer of the bottom plates, the assembled workpieces and the finished products is automatically completed through a truss manipulator, and traditional manual carrying is replaced; in the assembling link, the carrying robot grabs the parts through a multifunctional gripper integrating an electromagnet and a clamping jaw, after precise positioning is achieved through cooperation with a secondary positioning platform, point fixing is automatically completed through the welding robot, and the positions of the parts do not need to be manually adjusted. In the welding link, a six-axis welding robot and an H-shaped positioner work cooperatively, and welding seam locating, tracking and multi-layer and multi-pass welding are automatically completed.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation manufacturing technology, and specifically relates to an automatic cable trough assembly and welding system. Background Technology

[0002] Cable troughs are core structural components in the coal mining machinery field. Their manufacturing precision and welding quality directly affect the safety and reliability of coal mining equipment operation, and are key components to ensure continuous and stable underground operations. Currently, the assembly and welding production of cable troughs in the industry is still mainly based on traditional manual methods. This method has significant technical drawbacks in terms of production efficiency, assembly precision, changeover flexibility, and quality stability, making it difficult to meet the demands of modern industry for multi-variety and variable-batch production. Specific problems are as follows: 1. High reliance on manual labor, high labor intensity, and insufficient assembly precision: In traditional production processes, the positioning of the cable trough's base plate, the handling of components, the assembly and clamping, and some welding processes all require manual operation. On the one hand, manual handling of heavy plates and profiles is labor-intensive, and fatigue can easily lead to component placement deviations. On the other hand, manual assembly is prone to positioning errors, such as difficulty in ensuring concentricity of holes in the base plate and back plate, and misalignment of stiffening plates, directly affecting the smooth progress of subsequent assembly processes. In addition, due to the special structure of the cable trough, manual welding is required, which not only further increases labor costs but may also lead to a decrease in product consistency due to the randomness of welding operations.

[0003] 2. Low production efficiency, making it difficult to adapt to batch production needs: In the traditional model, the transfer of workpieces and the adjustment of tooling are all done manually. The time spent on each workpiece transfer and tooling calibration is long, which significantly increases the assembly and welding cycle of a single cable trough, making it impossible to meet the cycle time requirements of batch production. At the same time, due to the design characteristics of cable troughs, such as the narrow internal space, manual operation of the welding torch is prone to problems with poor torch accessibility. That is, the welding torch cannot penetrate into specific weld positions inside the workpiece, requiring subsequent manual welding to complete the welding, further extending the production cycle and reducing overall production efficiency.

[0004] 3. Poor adaptability to model changes and inability to quickly respond to multi-variety production: Cable troughs have diverse specifications and parameters, with significant differences between different models. Traditional production uses fixed tooling structures. When changing production models, the tooling needs to be disassembled, reassembled, and recalibrated. The model changeover process is time-consuming and complex, making it difficult to quickly switch production specifications and respond to the market's demand for flexible production of multi-variety cable troughs.

[0005] 4. Poor quality stability and high risk of welding defects. On the one hand, the quality of manual welding is highly dependent on the experience level of the operators. Differences in welding techniques and parameter control among different personnel lead to low weld uniformity and are prone to surface defects such as uneven weld height and undercut. On the other hand, traditional production lacks a real-time monitoring mechanism for key welding process parameters. For example, fluctuations in shielding gas pressure and abnormal water tank temperature cannot be promptly alerted, easily causing internal defects such as porosity and incomplete penetration. Furthermore, if robot-assisted welding is used, it requires high precision in upstream processes. Fluctuations in the precision of traditional manual pretreatment processes can further degrade the quality of robot welding, exacerbating product quality instability.

[0006] In summary, traditional cable trough assembly and welding technologies can no longer meet the comprehensive requirements of modern production for efficiency, precision, flexibility, and quality. There is an urgent need to develop an automated cable trough assembly and welding system with high integration, flexibility, and automation to solve many of the pain points of existing technologies and promote the upgrading of cable trough production towards automation and intelligence. Summary of the Invention

[0007] To address the technical problems existing in the traditional cable trough assembly and welding technology, the present invention provides an automatic cable trough assembly and welding system.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: An automatic cable trough assembly and welding system includes an automatic assembly station, an automatic welding station, a logistics transfer system, and an integrated control system. The automatic assembly station is located in the lower middle area of ​​the logistics transfer system, and the automatic welding stations are arranged linearly adjacent to one side of the automatic assembly station. The integrated control system is located in a ground control cabinet on the side of the automatic welding station away from the automatic assembly station. The integrated control system is electrically connected to the automatic assembly station, the automatic welding station, and the logistics transfer system via shielded signal cables to realize the action control and data interaction of each system. The moving end of the logistics transfer system covers the workpiece carrying areas of both the automatic assembly station and the automatic welding station, and is used to complete the workpiece transfer between the two stations. The workpiece output end of the automatic assembly station corresponds to the input end of the logistics transfer system, and the workpiece input end of the automatic welding station corresponds to the output end of the logistics transfer system.

[0009] The automated assembly station includes an assembly fixture, a secondary positioning platform, a transport robot, and an assembly spot welding robot. The assembly fixture is fixed to the central ground of the automated assembly station. Four sets of secondary positioning platforms are evenly and linearly distributed on one side of the assembly fixture. The transport robot is installed on a ground base between the assembly fixture and the secondary positioning platform. The assembly spot welding robot is fixed to the ground on the other side of the assembly fixture away from the secondary positioning platform. The end of the transport robot is detachably connected to a multi-functional gripper via bolt flanges. Its working range covers the positioning areas of all secondary positioning platforms and the workpiece placement area of ​​the assembly fixture. The working range of the assembly spot welding robot covers the entire area of ​​the assembly fixture and is used to spot weld the parts placed on the assembly fixture by the transport robot. The top of the assembly fixture has a side-pushing mechanism along its length and width, and a clamping mechanism is vertically installed on the top. Both the side-pushing mechanism and the clamping mechanism are connected to a pneumatic pump station next to the automated assembly station via air pipes, and their actions are controlled by an integrated control system.

[0010] The automated welding station includes a welding robot, a dedicated welding torch, a welding power source, an H-type positioner, and a torch cleaning system. The welding robot is fixed to one side of the automated welding station. The H-type positioner is positioned within the welding robot's working range and at the center of the automated welding station. The welding power source is placed on a ground support next to the welding robot. The torch cleaning system is fixed to the ground between the welding robot and the H-type positioner. The end effector of the welding robot is detachably connected to the dedicated welding torch via a quick-connect coupling. The dedicated welding torch is electrically connected to the output end of the welding power source via a welding cable and to the gas output port of the welding power source via a protective gas pipe. The H-type positioner is electrically connected to the welding robot via a signal cable to synchronize their movements. The cleaning station of the torch cleaning system corresponds to the movement trajectory of the dedicated welding torch. It is connected to a compressed air source via a gas pipe and to an integrated control system via a signal line.

[0011] The logistics transfer system includes a gantry robot and a material rack system. The gantry robot is bolted to a steel beam above the automatic assembly station and automatic welding station, with both ends of the beam fixed to columns on the workshop floor. The material rack system is located on the ground away from the assembly tooling on the secondary positioning platform of the automatic assembly station. The moving slider of the gantry robot engages with the beam via a gear and rack mechanism, and its bottom gripping mechanism is connected to the drive unit of the gantry robot via a cable. The movement range of the gripping mechanism covers the assembly tooling of the automatic assembly station, the H-type positioner of the automatic welding station, the bottom plate loading station of the workshop, and the finished product unloading station. The material rack system includes multi-layer component trays and tray positioning components. The tray positioning components engage with the bottom positioning holes of the component trays via positioning pins to fix the component trays. The placement height of the component trays corresponds to the gripping height of the handling robot.

[0012] The integrated control system includes a human-machine interface, a forced cooling water tank, and a pressure sensor. The human-machine interface is embedded in the control cabinet panel of the integrated control system. The forced cooling water tank is placed on the ground next to the welding robot at the automatic welding station. The pressure sensor is connected in series to the front end of the protective gas pipeline. The human-machine interface is electrically connected to the core controller of the integrated control system via a data cable for parameter input and status display. The forced cooling water tank is connected to both ends of the cooling channel inside the dedicated welding torch via a cooling water pipe, forming a closed-loop water circuit. The liquid level sensor built into the forced cooling water tank is electrically connected to the integrated control system via a signal line. The pressure sensor is electrically connected to the integrated control system via a signal cable for real-time detection of protective gas pressure and data feedback.

[0013] The secondary positioning platform is equipped with a sheet metal positioning block, a round tube positioning V-block, and a positioning cylinder at its top. There are two sheet metal positioning blocks, which are located at both ends of the length direction of the top of the secondary positioning platform. The round tube positioning V-block is fixed to the center of the top of the secondary positioning platform. The positioning cylinder is installed in the bottom cavity of the secondary positioning platform. Its piston rod passes through the top surface of the secondary positioning platform and is fixedly connected to the bottom of the sheet metal positioning block, driving the sheet metal positioning block to move along the length direction of the secondary positioning platform.

[0014] The H-type positioner includes a cable trough positioning clamp, a fixed base, a tilting frame, and a drive assembly. The fixed base is fixed to the ground. The tilting frame is rotatably connected to the bearing seats on the top of the fixed base via two rotating shafts. The cable trough positioning clamp is fixed to the top platform of the tilting frame with bolts. The drive assembly is installed in a cavity on one side of the fixed base. Its output end is connected to one rotating shaft of the tilting frame via a coupling. The drive assembly drives the tilting frame to tilt the cable trough positioning clamp.

[0015] An automatic cable trough assembly and welding method includes the following steps: Step 1: Material preparation. Manually place the cable trough bottom plate on the corresponding bottom plate loading station of the logistics transfer system. Classify and place the upright plate, stiffening plate, and process support into the component tray of the material rack system. Input the workpiece model through the human-machine interface of the integrated control system. Step 2: Base plate positioning. The truss robot of the logistics transfer system grabs the base plate and transfers it to the assembly tooling at the automatic assembly station. The side push mechanism and clamping mechanism of the assembly tooling fix the base plate. Step 3: Component assembly. The handling robot picks up the components from the rack system, transports them to the secondary positioning platform for positioning, and then places them on the base plate of the assembly tooling. The assembly and spot welding robot performs spot welding. The pipe assembly is prefabricated by spot welding after being positioned by the secondary positioning platform, and then transported to the base plate for spot welding. Step 4: Workpiece transfer. The gantry robot grabs the assembled and fixed cable trough and transfers it to the H-type positioner at the automatic welding station. The cable trough positioning fixture clamps the workpiece. Step 5: Automated welding. The integrated control system controls the welding robot to move the special welding torch to the weld position. The H-type positioner flips to adjust the weld angle. The welding power supply is started to weld. After welding is completed, the special welding torch is moved to the torch cleaning system for cleaning. Step 6: Finished product unloading. After welding is completed, the H-type positioner is reset, and the gantry robot grabs the finished product and transfers it to the unloading station for manual handling. Step 7: Change of workpiece model. When changing the workpiece model, manually adjust the side push mechanism and clamping mechanism of the tooling, the plate positioning block of the secondary positioning platform, and the position of the multi-functional gripper of the handling robot.

[0016] Compared with the prior art, the beneficial effects of this invention are: 1. This invention achieves fully automated operation of cable troughs from bulk material loading to finished product unloading, significantly reducing reliance on manual labor and labor intensity. In the logistics stage, a gantry robot automatically transfers base plates, assembled workpieces, and finished products across workstations, replacing traditional manual handling. In the assembly stage, a handling robot uses a multi-functional gripper integrating electromagnets and clamps to grasp components, achieving precise positioning with a secondary positioning platform, followed by automatic tack welding by a welding robot, eliminating the need for manual adjustment of component positions. In the welding stage, a six-axis welding robot and an H-type positioner work together to automatically complete weld seam positioning, tracking, and multi-layer, multi-pass welding. The entire process requires only manual intervention for initial material loading, finished product turnover, and simple adjustments during changeovers, freeing workers from the heavy and dangerous welding environment while significantly reducing labor costs and operational safety risks.

[0017] 2. This invention optimizes the production process and core equipment configuration to achieve high-efficiency production cycles, fully meeting the needs of mass production. The material rack system supports continuous material supply for multiple sets of components without production interruption, and the gantry robot enables seamless connection between various workstations, avoiding the waiting time for manual workpiece handling. The welding power supply supports high-current welding with 100% duty cycle for extended periods, and the H-type positioner can adjust the weld to the optimal welding position, such as flat welding or 45° welding, effectively solving the problem of re-welding caused by "poor accessibility of welding torch" in traditional production. Combined with the automatic torch cleaning system's 20-second / cycle cleaning operation, welding interruption time is significantly reduced.

[0018] 3. This invention employs multiple technical means to strictly control assembly and welding precision, effectively ensuring product consistency and subsequent assembly compatibility. During the assembly stage, the assembly tooling achieves high-precision positioning of the base plate through a side-pushing mechanism and a clamping mechanism. The secondary positioning platform compensates for material errors by using cylinder-driven positioning blocks and V-blocks, completely resolving assembly issues such as misalignment of holes in the base plate and back plate, and misalignment of stiffeners during traditional manual assembly. During the welding stage, a six-axis robot with arc tracking function can correct weld deviations in real time. A non-standard, extended air-cooled welding torch can penetrate deep into the workpiece to complete precise welding, avoiding welding defects such as porosity and incomplete penetration, ensuring uniform weld formation, and significantly improving product consistency.

[0019] 4. This invention possesses high flexibility and adaptability, enabling rapid response to the production needs of various cable troughs and solving the pain points of difficult and time-consuming tooling changeovers in traditional methods. Regarding tooling adaptation, assembling the tooling and secondary positioning platform only requires manual adjustment of the positioning blocks, clamping mechanisms, or gripper positions to adapt to different specifications of cable troughs, eliminating the need for disassembly and reassembly of the tooling. In terms of program management, the integrated control system supports rapid switching of workpiece models via a human-machine interface, directly calling corresponding welding parameters and robot motion trajectories. Combined with USB flash drive program backup and restore functions, it can flexibly handle production orders with multiple varieties and varying batch sizes.

[0020] 5. This invention ensures high stability and reliability in the production process and significantly reduces quality risks through high-quality hardware selection and full-process process monitoring. At the hardware level, the H-type positioner has a load capacity of up to 2 tons and a repeatability accuracy of <±0.2mm. The forced-cooling water tank effectively prevents welding torch damage due to overheating. The torch cleaning system avoids welding spatter adhesion through wire cutting, nozzle cleaning, and silicone oil spraying, reducing malfunctions at the equipment foundation level. At the monitoring level, the integrated control system monitors key parameters such as protective gas pressure, water tank level, and welding current and voltage in real time. In case of abnormalities, it can automatically alarm or pause the equipment to avoid welding defects caused by parameter fluctuations. Simultaneously, robotic automated welding replaces manual operation, eliminating uneven weld quality caused by differences in operator experience, increasing the product qualification rate to over 99%.

[0021] 6. This invention adopts a unified control architecture to achieve high integration and intelligent management of various systems, effectively improving production management efficiency. This architecture integrates and coordinates the robot system, external axis system, welding system, and all peripheral equipment to ensure precise coordination of actions in each stage. At the operational level, the human-machine interface can intuitively display the operating status of each workstation, production cycle time, and fault information, facilitating operators to monitor the production process in real time and quickly troubleshoot problems. At the data management level, the system supports program backup and recovery via USB flash drive, facilitating standardized management and traceability of production parameters, reducing production interruptions caused by parameter loss, and promoting the upgrading of workshop production management towards standardization and efficiency. Attached Figure Description

[0022] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0023] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the automatic assembly station of the present invention; Figure 3 This is a schematic diagram of the secondary positioning platform of the present invention; Figure 4 This is a schematic diagram of the automatic welding station of the present invention.

[0025] Among them: 1 is the automatic assembly station, 2 is the automatic welding station, 3 is the logistics transfer system, 4 is the integrated control system, 101 is the assembly tooling, 1011 is the side push mechanism, 1012 is the clamping mechanism, 102 is the secondary positioning platform, 1021 is the plate positioning block, 1022 is the round tube positioning V-block, 1023 is the positioning cylinder, 103 is the handling robot, 1031 is the multi-functional gripper, 104 is the assembly spot welding robot, 201 is the welding robot, 202 is the special welding gun, 204 is the H-type positioner, 2041 is the cable trough positioning fixture, 2042 is the fixed base, 2043 is the flipping frame, 2044 is the drive component, 205 is the gun cleaning system, 301 is the gantry robot, 302 is the material rack system, 3021 is the component tray, 3022 is the tray positioning component, 401 is the human-machine interface, and 402 is the forced cooling water tank. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. These descriptions are only for further illustrating the features and advantages of the present invention, and not for limiting the claims of the present invention. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0027] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0028] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" 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 mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0029] This embodiment provides an automatic cable trough assembly and welding system, such as... Figures 1-4 As shown, the integrated control system 4 serves as the core command unit, and unified action control and data interaction are achieved for the automatic assembly station 1, automatic welding station 2, and logistics transfer system 3 through shielded signal cables. The specific working principle is as follows: I. System Initialization and Material Loading Preparation Phase First, the model parameters of the cable trough to be produced are input through the human-machine interface 401 of the integrated control system 4. The system automatically calls the matching assembly and welding programs. Simultaneously, manual initial material loading is completed: the cable trough base plate is placed on the corresponding base plate loading station of the logistics transfer system 3. Components such as uprights, stiffeners, and process supports are placed into the component trays 3021 of the material rack system 302 according to their categories. The component trays 3021 are fixed by the positioning pins of the tray positioning component 3022 engaging with the positioning holes at the bottom of the component trays 3021 (the placement height of the component trays 3021 is adapted to the gripping height of the handling robot 103 to ensure smooth subsequent gripping). During this stage, the pressure sensor of the integrated control system 4 monitors the pressure of the protective gas pipeline in real time, and the built-in liquid level sensor of the forced cooling water tank 402 monitors the water tank level. If the parameters are abnormal, the system alarms through the human-machine interface 401 to prevent starting with a fault.

[0030] II. Base Plate Positioning Stage After receiving instructions from the integrated control system 4, the gantry robot 301 of the logistics transfer system 3 moves its sliding block along the steel beams erected above each workstation via a gear and rack mechanism, and the bottom gripping mechanism moves down to grip the bottom plate of the bottom plate loading station; then the gantry robot 301 carries the bottom plate to the assembly fixture 101 of the automatic assembly station 1 and precisely places the bottom plate on the table of the assembly fixture 101; the integrated control system 4 synchronously controls the side push mechanism 1011 and the clamping mechanism 1012 of the assembly fixture 101 to operate (the side push mechanism 1011 and the clamping mechanism 1012 are connected to the pneumatic pump station next to the automatic assembly station 1 through air pipes, and the air supply is controlled by the system): the side push mechanism 1011 pushes the bottom plate to the preset positioning position along the length and width of the assembly fixture 101, and the clamping mechanism 1012 moves vertically down to clamp the bottom plate, realizing the stable positioning of the bottom plate and laying the foundation for subsequent component assembly.

[0031] III. Component Assembly and Tightening Stage The handling robot 103 at the automatic assembly station 1 starts according to the command. Its end-effector, a multi-functional gripper 1031 connected by bolt flanges, is adapted to different parts types: when gripping upright plates and stiffeners, the gripper's electromagnet is activated; when gripping round pipes, the grippers on both sides are activated. The handling robot 103 first moves to the parts tray 3021 of the material rack system 302 to grab the target parts, and then transfers them to the secondary positioning platform 102 (4 sets of secondary positioning platforms 102 are evenly and linearly distributed on one side of the assembly tooling 101, covering different parts positioning requirements). The positioning cylinder 1023 of the secondary positioning platform 102 (installed in the bottom cavity of the platform) drives the plate positioning block 1021 (2 plate positioning blocks 1021 are respectively positioned...). The robot moves horizontally at both ends of the platform top along the length direction to position sheet metal parts in the length and width directions. For tubular parts, radial centering is achieved through the tubular positioning V-block 1022 at the center of the top of the secondary positioning platform 102 to compensate for material errors. After positioning, the handling robot 103 transfers the parts to the designated position of the base plate of the assembly tooling 101. The integrated control system 4 then controls the assembly spot welding robot 104 (fixed on the other side of the assembly tooling 101 away from the secondary positioning platform 102, with the working range covering the entire area of ​​the assembly tooling 101) to move to the connection between the parts and the base plate to complete spot welding and fix the relative position of the parts.

[0032] For the pipe assembly, the handling robot 103 first transports the pipe assembly parts to the secondary positioning platform 102 for positioning and clamping, and then uses the spot welding gun on the multi-functional gripper 1031 to spot-fix the pipe assembly parts for prefabrication. After prefabrication, the handling robot 103 transfers the pipe assembly as a whole to the corresponding installation position on the base plate, and the assembly spot-fixing welding robot 104 spots-fixes it again. The above process is repeated to complete the assembly and spot-fixing of all vertical plates, stiffening plates and pipe assemblies in sequence. Finally, the handling robot 103 grabs the hanging plate, performs secondary positioning and spot-fixing, to form the cable trough assembly.

[0033] IV. Workpiece Transfer and Automated Welding Stage The integrated control system 4 controls the truss robot 301 to move again. Its gripping mechanism adapts to the size of the cable trough assembly and, after gripping the assembly, transports it along the crossbeam to the H-type positioner 204 of the automatic welding station 2 (located in the center of the automatic welding station 2, within the working range of the welding robot 201). The cable trough positioning clamp 2041 of the H-type positioner 204 (fixed to the top platform of the flipping frame 2043) then clamps the assembly to prevent welding displacement. The system synchronously starts the welding process: the special welding torch 202, connected to the end of the welding robot 201 (fixed to one side of the automatic welding station 2) via a quick-connect coupling, moves to the weld start position. The integrated control system 4 controls the welding power supply (placed on the ground support next to the welding robot 201) to start. The special welding torch 202 obtains welding current through the welding cable and passes through the protective shield. The gas pipe receives the protective gas output from the welding power source, and the welding operation begins. Simultaneously, the drive assembly 2044 of the H-type positioner 204 (installed in one cavity of the fixed base 2042) drives the tilting frame 2043 (rotatably connected to the top bearing seat of the fixed base 2042 via a rotating shaft) to tilt, adjusting the weld to the optimal position such as flat welding or 45° welding, solving the problem of poor accessibility of the welding torch. During the welding interval, the welding robot 201 moves the dedicated welding torch 202 to the torch cleaning system 205 (fixed on the ground between the welding robot 201 and the H-type positioner 204, with the cleaning station corresponding to the movement trajectory of the dedicated welding torch 202). The torch cleaning system 205 is connected to compressed air through the gas pipe, driving the internal rotating blade to clean the nozzle spatter. At the same time, the wire cutting mechanism cuts the welding wire, and the silicone oil spraying mechanism sprays silicone oil to prevent spatter adhesion.

[0034] During this stage, the forced cooling water tank 402 (placed next to the welding robot 201) forms a closed-loop water circuit with the internal cooling channel of the special welding torch 202 through the cooling water pipe, which cools the special welding torch 202; the pressure sensor continuously monitors the protective gas pressure, and if the parameter is abnormal, the integrated control system 4 immediately suspends welding and alarms.

[0035] V. Finished Product Cutting and Changeover Adjustment Stage After welding is completed, the integrated control system 4 controls the H-type positioner 204's flipping frame 2043 to reset to the initial position, and the cable trough positioning clamp 2041 releases the finished product; the gantry robot 301 grabs the finished cable trough and transfers it along the crossbeam to the finished product unloading station, where it is manually unloaded.

[0036] When changing the cable trough model, the operator selects the new workpiece model through the human-machine interface 401, and the system calls the corresponding program. At the same time, the operator adjusts the key components to adapt to the new dimensions: adjusts the positioning reference of the side push mechanism 1011 and the clamping mechanism 1012 of the assembly tooling 101, adjusts the fixed position of the plate positioning block 1021 and the round tube positioning V-block 1022 of the secondary positioning platform 102, and adjusts the installation angle and gripping parameters of the multi-functional gripper 1031 of the handling robot 103. After the model change is completed, the production of the new model cable trough can be started.

[0037] The above description only illustrates the preferred embodiments of the present invention. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention, and all such changes should be included within the protection scope of the present invention.

Claims

1. An automatic cable trough assembly and welding system, characterized in that: The system includes an automatic assembly station (1), an automatic welding station (2), a logistics transfer system (3), and an integrated control system (4). The automatic assembly station (1) is located in the lower middle area of ​​the logistics transfer system (3). The automatic welding station (2) is arranged linearly on one side of the automatic assembly station (1). The integrated control system (4) is located in a ground control cabinet on the side of the automatic welding station (2) away from the automatic assembly station (1). The integrated control system (4) is electrically connected to the automatic assembly station (1), the automatic welding station (2), and the logistics transfer system (3) through shielded signal cables to realize the action control and data interaction of each system. The moving end of the logistics transfer system (3) covers the workpiece carrying area of ​​the automatic assembly station (1) and the workpiece carrying area of ​​the automatic welding station (2) to complete the workpiece transfer between the two stations. The workpiece output end of the automatic assembly station (1) corresponds to the input end of the logistics transfer system (3), and the workpiece input end of the automatic welding station (2) corresponds to the output end of the logistics transfer system (3).

2. The automatic cable trough assembly and welding system according to claim 1, characterized in that: The automatic assembly station (1) includes an assembly fixture (101), a secondary positioning platform (102), a transport robot (103), and an assembly spot welding robot (104). The assembly fixture (101) is fixed to the central ground of the automatic assembly station (1). The secondary positioning platform (102) has four sets and is evenly and linearly distributed on one side of the assembly fixture (101). The transport robot (103) is installed on the ground base between the assembly fixture (101) and the secondary positioning platform (102). The assembly spot welding robot (104) is fixed to the ground on the other side of the assembly fixture (101) away from the secondary positioning platform (102). The end of the transport robot (103) is connected to a multi-functional... The gripper (1031) is detachable and its working range covers the positioning area of ​​all secondary positioning platforms (102) and the workpiece placement area of ​​the assembly tooling (101); the working range of the assembly spot welding robot (104) covers the entire area of ​​the assembly tooling (101) and is used to spot fix the parts placed on the assembly tooling (101) by the handling robot (103); the top of the assembly tooling (101) is provided with a side push mechanism (1011) along its own length and width direction, and a clamping mechanism (1012) is provided vertically on the top. The side push mechanism (1011) and the clamping mechanism (1012) are both connected to the pneumatic pump station next to the automatic assembly station (1) through air pipes and are controlled by the integrated control system (4).

3. The automatic cable trough assembly and welding system according to claim 1, characterized in that: The automatic welding station (2) includes a welding robot (201), a special welding torch (202), a welding power source, an H-type positioner (204), and a torch cleaning system (205). The welding robot (201) is fixed to one side of the automatic welding station (2). The H-type positioner (204) is located within the working range of the welding robot (201) and in the center of the automatic welding station (2). The welding power source is placed on a ground support next to the welding robot (201). The torch cleaning system (205) is fixed between the welding robot (201) and the H-type positioner (204). The ground between; the end of the welding robot (201) is detachably connected to the special welding gun (202) via a quick-connect connector. The special welding gun (202) is electrically connected to the output end of the welding power supply via a welding cable and connected to the gas output port of the welding power supply via a protective gas pipe; the H-type positioner (204) is electrically connected to the welding robot (201) via a signal cable to achieve synchronous movement of the two; the cleaning station of the cleaning system (205) corresponds to the movement trajectory of the special welding gun (202). It is connected to the compressed air source via a gas pipe and electrically connected to the integrated control system (4) via a signal line.

4. The automatic cable trough assembly and welding system according to claim 1, characterized in that: The logistics transfer system (3) includes a gantry robot (301) and a material rack system (302); the gantry robot (301) is bolted to a steel beam above the automatic assembly station (1) and the automatic welding station (2), with both ends of the beam fixed to the workshop floor columns; the material rack system (302) is located on the side of the automatic assembly station (1) away from the assembly tooling (101) of the secondary positioning platform (102); the moving slider of the gantry robot (301) cooperates with the beam through a gear and rack mechanism, and its bottom gripping mechanism is connected to the drive of the gantry robot (301) through a cable. The unit is connected, and the range of motion of the gripping mechanism covers the assembly tooling (101) of the automatic assembly station (1), the H-type positioner (204) of the automatic welding station (2), the bottom plate loading station and the finished product unloading station of the workshop; the rack system (302) includes a multi-layer part tray (3021) and a tray positioning component (3022). The tray positioning component (3022) is engaged with the bottom positioning hole of the part tray (3021) through the positioning pin to fix the part tray (3021). The placement height of the part tray (3021) corresponds to the gripping height of the handling robot (103).

5. The automatic cable trough assembly and welding system according to claim 1, characterized in that: The integrated control system (4) includes a human-machine interface (401), a forced cooling water tank (402), and a pressure sensor. The human-machine interface (401) is embedded in the control cabinet panel of the integrated control system (4). The forced cooling water tank (402) is placed on the ground next to the welding robot (201) of the automatic welding station (2). The pressure sensor is connected in series to the front end of the protective gas pipeline. The human-machine interface (401) is electrically connected to the core controller of the integrated control system (4) through a data cable for parameter input and status display. The forced cooling water tank (402) is connected to both ends of the cooling channel inside the special welding gun (202) through a cooling water pipe to form a closed-loop water circuit. The liquid level sensor built into the forced cooling water tank (402) is electrically connected to the integrated control system (4) through a signal line. The pressure sensor is electrically connected to the integrated control system (4) through a signal cable for real-time detection of protective gas pressure and feedback of data.

6. The automatic cable trough assembly and welding system according to claim 2, characterized in that: The secondary positioning platform (102) is provided with a plate positioning block (1021), a round tube positioning V-block (1022) and a positioning cylinder (1023) on the top. There are two plate positioning blocks (1021) and they are located at both ends of the length direction of the top of the secondary positioning platform (102). The round tube positioning V-block (1022) is fixed in the center of the top of the secondary positioning platform (102). The positioning cylinder (1023) is installed in the bottom cavity of the secondary positioning platform (102). Its piston rod passes through the top surface of the secondary positioning platform (102) and is fixedly connected to the bottom of the plate positioning block (1021), driving the plate positioning block (1021) to move along the length direction of the secondary positioning platform (102).

7. The automatic cable trough assembly and welding system according to claim 3, characterized in that: The H-type positioner (204) includes a cable trough positioning clamp (2041), a fixed base (2042), a flipping frame (2043), and a drive assembly (2044). The fixed base (2042) is fixed to the ground. The flipping frame (2043) is rotatably connected to the bearing seat on the top of the fixed base (2042) through two rotating shafts. The cable trough positioning clamp (2041) is fixed to the top platform of the flipping frame (2043) by bolts. The drive assembly (2044) is installed in one side cavity of the fixed base (2042). Its output end is connected to one end of the rotating shaft of the flipping frame (2043) through a coupling. The drive frame (2043) drives the cable trough positioning clamp (2041) to flip.

8. A method for automatic cable trough assembly and welding according to any one of claims 1-7, characterized in that, Includes the following steps: Step 1, Material preparation: Manually place the cable trough bottom plate on the corresponding bottom plate loading station of the logistics transfer system (3), and classify the upright plate, stiffening plate and process support into the component tray (3021) of the material rack system (302). Input the workpiece model through the human-machine interface (401) of the integrated control system (4). Step 2: Base plate positioning. The truss robot (301) of the logistics transfer system (3) grabs the base plate and transfers it to the assembly tooling (101) of the automatic assembly station (1). The side push mechanism (1011) and the clamping mechanism (1012) of the assembly tooling (101) fix the base plate. Step 3: Component assembly. The handling robot (103) picks up the components from the rack system (302), transfers them to the secondary positioning platform (102) for positioning, and places them on the base plate of the assembly tooling (101). The assembly spot welding robot (104) performs spot welding. After the pipe assembly is positioned by the secondary positioning platform (102), it is prefabricated by the handling robot (103) and then transferred to the base plate for spot welding. Step 4: Workpiece transfer. The gantry robot (301) grabs the assembled and fixed cable trough and transfers it to the H-type positioner (204) of the automatic welding station (2). The cable trough positioning fixture (2041) clamps the workpiece. Step 5: Automated welding. The integrated control system (4) controls the welding robot (201) to move the special welding gun (202) to the weld position. The H-type positioner (204) flips to adjust the weld angle. The welding power supply starts welding. After welding is completed, the special welding gun (202) moves to the cleaning system (205) for cleaning. Step 6: Finished product unloading. After welding is completed, the H-type positioner (204) is reset, and the gantry robot (301) grabs the finished product and transfers it to the unloading station for manual turnover. Step 7: Change of type and adjustment. When changing the workpiece model, the manual adjustment group adjusts the position of the side push mechanism (1011) and clamping mechanism (1012) of the tooling (101), the plate positioning block (1021) of the secondary positioning platform (102), and the multi-functional gripper (1031) of the handling robot (103).

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