Automatic bearing carrier roller welding device and method

Abstract

The invention relates to the technical field of welding equipment, and discloses an automatic bearing carrier roller welding device and method. The device comprises a rotary driving assembly, a supporting and clamping assembly, a follow-up translation assembly and two welding assemblies, wherein the rotary driving assembly, the supporting and clamping assembly and the follow-up translation assembly are sequentially arranged side by side in the same direction, and the two welding assemblies are located at the two ends of the supporting and clamping assembly and used for welding the bearing carrier roller. According to the device, through cooperative layout of rotary driving, supporting clamping, follow-up translation and a double-welding assembly, the elastic self-adaptive clamping and lifting calibration functions of the supporting clamping assembly are combined, and the two-end jacking rotation design of follow-up translation and rotary driving is adopted, so that automatic integrated operation of carrier roller welding is achieved; the adaptability and the positioning welding accuracy of the carrier rollers of multiple specifications are improved, the efficiency is improved through double-end synchronous welding, the welding seam quality is guaranteed, meanwhile, labor dependence is reduced, and the large-scale standardized production requirement is met.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and more specifically, to an automated welding device and method for load-bearing idlers. Background Technology

[0002] As the core load-bearing and operating component of belt conveyors, the manufacturing quality of load-bearing idlers directly affects the resistance, energy consumption, noise, and reliability of the entire machine. In heavy-duty fields such as coal mining, ports, and power generation, large belt conveyor systems may require thousands of idlers, making the stability and consistency of their performance crucial.

[0003] Traditional manufacturing processes for load-bearing idlers mainly fall into two categories: one uses cast iron bearing housings, which are pressed into stepped holes machined at both ends of the idler steel pipe; the other uses stamped bearing housings or end caps, which are then fixed to both ends of the steel pipe using welding processes (such as CO2 gas shielded welding). Among these, welding has become the mainstream manufacturing method due to its advantages such as high connection strength, lightweight structure, and high production efficiency.

[0004] The following technical challenges and pain points are commonly found in the traditional welding process for load-bearing idlers: Low clamping and positioning efficiency and poor adaptability: Traditional welding fixtures mostly use rigid clamps, which require manual adjustment of clamping parameters according to different diameters and lengths of idler rollers. The clamping process is cumbersome and the changeover time is long. Moreover, rigid clamping is prone to scratches on the surface of the idler rollers, especially for thin-walled cylinders, where the risk of damage is even higher.

[0005] Insufficient coaxiality control precision: The welding of idler rollers requires ensuring the coaxiality of the cylinder and the shaft head; otherwise, it will cause eccentric vibration when the idler roller rotates. The support and positioning mechanisms of traditional tooling are independent of each other, and height adjustment and coaxial calibration require repeated manual measurements. The calibration accuracy is greatly affected by the operator's experience, and problems such as weld misalignment and uneven penetration are prone to occur.

[0006] Poor stability of rotational welding: Some traditional tooling adopts a single-sided drive and single-sided support structure. During the rotation of the roller, axial movement or radial sway is prone to occur, resulting in poor consistency of the width and penetration depth of the circumferential weld. At the same time, the sliding friction resistance between the roller and the tooling is large, which not only increases the driving energy consumption, but also wears the surface of the roller. Summary of the Invention

[0007] The purpose of this invention is to provide an automated welding device and method for load-bearing idlers to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, on the one hand, the present invention provides an automated load-bearing idler welding device, including a rotary drive assembly, a support clamping assembly, a follow-up translation assembly arranged in parallel along the same direction, and two welding assemblies located at both ends of the support clamping assembly for welding the load-bearing idler. The support and clamping assembly includes a lifting mechanism, a support mechanism disposed on the lifting mechanism, and an elastic clamping mechanism disposed on the support mechanism. When the load-bearing roller is placed on the support mechanism, the elastic clamping mechanism automatically clamps the side wall of the load-bearing roller by its own elastic force. The lifting mechanism is used to drive the support mechanism and the clamping mechanism to move up and down. The follower translation component can move linearly relative to the support clamping component. During the movement, the follower translation component cooperates with the rotary drive component to clamp both ends of the load-bearing roller. The rotary drive component can drive the load-bearing roller to rotate.

[0009] Preferably, the support mechanism includes two support groups spaced apart along the length of the load-bearing idler roller. Each support group includes a bracket and a first idler roller group arranged in a V-shape on the bracket. The arrangement direction of the first idler roller group is perpendicular to the length direction of the load-bearing idler roller.

[0010] Preferably, the lifting mechanism includes two lifting parts disposed at the bottom of the corresponding bracket. Each lifting part includes a chassis, a rotating cylinder rotatably connected to the chassis, a threaded rod threadedly connected to the rotating cylinder, and a mounting head disposed at the top of the threaded rod. The end of the mounting head away from the threaded rod is connected to the bracket.

[0011] Preferably, the elastic clamping mechanism includes two elastic clamping parts disposed at the first and second ends of the two brackets, the two elastic clamping parts being symmetrical about the load-bearing roller axis. Each elastic clamping part includes a transverse shaft rotatably connected between the first or second ends of the two brackets, a linkage member disposed on the transverse shaft, a second connecting part disposed on the linkage member and inclined upward, a swing frame rotatably disposed on the second connecting part, a second roller rotatably connected to the swing frame, and an elastic member connecting the two swing frames. The second roller is arranged in the same direction as the length direction of the load-bearing roller. The swing frames are relatively squeezed and clamped by the elastic member.

[0012] Preferably, the elastic clamping mechanism further includes a second guide portion that provides guidance for the clamping movement of the two elastic clamping portions. The second guide portion includes two first connecting portions disposed on the bottom side of the two linkage members and two telescopic rods disposed on the two first connecting portions away from the linkage members. The opposite ends of the two telescopic rods are movably inserted into the connecting cylinder.

[0013] Preferably, the elastic clamping mechanism further includes a load-bearing frame disposed between the two brackets, the top surface of the load-bearing frame being arc-shaped to match the cross-section of the load-bearing roller, and the elastic element passing through the bottom of the load-bearing frame.

[0014] Preferably, the rotary drive assembly includes a servo motor and a reducer driven by the servo motor, a reduction mechanism driven by the reducer, and a first clamping part driven by the reduction mechanism, wherein the first clamping part abuts against one end of the load-bearing roller.

[0015] Preferably, the deceleration mechanism includes a drive shaft that is connected to the reducer, a second gear disposed on the drive shaft, a first gear that meshes with the second gear, and a rotating body connected to the first gear, wherein one end of the rotating body away from the first gear is connected to the first clamping part.

[0016] Preferably, the follow-up translation component includes a base, a slide rail disposed on the base, a slider slidably connected to the slide rail, a linear drive unit disposed on the base, and a second clamping unit disposed on the slider. The linear drive unit is used to drive the slider to move linearly toward the support clamping component until the second clamping unit cooperates with the rotary drive component to clamp the load-bearing roller.

[0017] On the other hand, the present invention also discloses a method for using the above-mentioned automated load-bearing idler roller welding device, comprising the following steps: Place the load-bearing idler roller to be welded on the support mechanism. At this time, the elastic clamping mechanism clamps the load-bearing idler roller under its elastic action. The lifting mechanism adjusts the height of the load-bearing roller so that the load-bearing roller, the first clamping part of the rotary drive assembly, and the second clamping part of the follow-up translation assembly are coaxial. The follow-up translation component moves toward the load-bearing idler roller, causing the first clamping part and the second clamping part to clamp the load-bearing idler roller together; The welding assembly is activated to weld the position to be welded on the load-bearing idler. During the welding process, the rotation drive assembly drives the load-bearing idler to rotate for welding.

[0018] The beneficial effects of this invention are as follows: By employing a coordinated layout of rotary drive, support clamping, follow-up translation, and dual welding components, combined with the elastic adaptive clamping and lifting calibration functions of the support clamping components, and the end-to-end clamping and rotation design of the follow-up translation and rotary drive, automated integrated operation of idler roller welding is achieved. This not only improves the adaptability of multi-specification idler rollers and the accuracy of positioning welding, but also increases efficiency and ensures weld quality through simultaneous welding at both ends, while reducing reliance on manual labor and meeting the needs of large-scale standardized production.

[0019] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the following detailed description to explain the invention, but do not constitute a limitation thereof. In the drawings: Figure 1 A modeling diagram of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown; Figure 2 A schematic diagram of the structure of an automated load-bearing idler welding device and a load-bearing idler according to an embodiment of the present invention is shown. Figure 3 A schematic diagram of the structure of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown; Figure 4 A schematic diagram of the rotary drive assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown. Figure 5 A schematic diagram showing the connection between the rear cover and the outer shell of the rotary drive assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown. Figure 6 An exploded view of the internal structure of the rotary drive assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown. Figure 7 A cross-sectional view along the first clamping portion of the rotary drive assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown. Figure 8 A schematic diagram of the support clamping assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown. Figure 9 A cross-sectional view along the telescopic rod is shown of the support clamping assembly of an automated load-bearing idler roller welding device according to an embodiment of the present invention. Figure 10 An exploded view of the lifting mechanism of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown; Figure 11 A schematic diagram of the follow-up translation component of an automated load-bearing idler roller welding device according to an embodiment of the present invention is shown.

[0021] Explanation of reference numerals in the attached figures: 1. Rotary drive assembly; 101. Servo motor; 102. Reducer; 103. Rotating body; 104. Housing; 105. First clamping head; 106. Locking nut; 107. Seal; 108. Threaded cylinder; 109. Welding assembly; 1010. Bearing; 1011. Connector; 1012. First gear; 1013. Drive shaft; 1014. Second gear; 1015. Locking screw; 1016. Rear cover; a. First cavity; b. Second cavity; 2. Support clamping assembly; 201. Bracket; 202. First roller group; 203. T-shaped mounting port; 204. First guide part; 204a. Guide cylinder; 204b. Guide rod; 205. Lifting part; 205a. Chassis; 205b. Rotating cylinder; 205c. Threaded rod; 205d. Mounting head; 206. Transverse shaft; 207. Linkage component; 208. First connecting part; 209. Telescopic rod; 2091. Connecting cylinder; 2010. Second connecting part; 2011. Swing frame; 2012. Second roller; 2013. Load-bearing frame; 2014. Elastic band; 3. Follow-up translation component; 301. Base; 302. Sliding body; 303. Second clamping head; 304. Linear drive unit; 305. Sub-frame. Detailed Implementation

[0022] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0023] Please refer to Figures 1-11 On the one hand, this embodiment discloses an automated load-bearing idler welding device, including a rotary drive assembly 1, a support clamping assembly 2, a follower translation assembly 3 arranged in parallel along the same direction, and two welding assemblies 109 (using CO2 gas shielded welding) located at both ends of the support clamping assembly 2 for welding the load-bearing idler. The support clamping assembly 2 includes a lifting mechanism, a support mechanism disposed on the lifting mechanism, and an elastic clamping mechanism disposed on the support mechanism. When the load-bearing roller is placed on the support mechanism, the elastic clamping mechanism automatically clamps the side wall of the load-bearing roller by its own elastic force. The lifting mechanism is used to drive the support mechanism and the clamping mechanism to move up and down. The follower translation component 3 can move linearly relative to the support clamping component 2. During the movement, the follower translation component 3 cooperates with the rotary drive component 1 to clamp the two ends of the load-bearing roller. The rotary drive component 1 can drive the load-bearing roller to rotate.

[0024] Specifically, the rotary drive assembly 1, the support clamping assembly 2, and the follower translation assembly 3 are arranged sequentially from right to left and are all mounted on the worktable 100. The support clamping assembly 2 is centrally positioned to support and initially fix the load-bearing idler roller. The rotary drive assembly 1 and the follower translation assembly 3 are located on either side of the worktable 100, responsible for final drive alignment and axial clamping. Two welding assemblies 109 are placed at both ends of the load-bearing idler roller to achieve synchronous welding. All components are arranged along the axial direction of the load-bearing idler roller to ensure the coaxiality and continuity of the force flow and the work flow.

[0025] During operation, the end caps are pre-assembled onto both ends of the load-bearing idler to be welded. The support mechanism and elastic clamping mechanism first receive and adaptively clamp the load-bearing idler. Subsequently, the lifting mechanism raises and lowers to level the load-bearing idler so that its axis coincides with the drive / clamping axis. The follow-up translation component 3 moves to the right, cooperating with the rotary drive component 1 to rigidly clamp the end caps at both ends of the load-bearing idler. Finally, the rotary drive component 1 drives the load-bearing idler to rotate at a uniform speed, and the welding component 109 uses CO2 gas shielded welding to perform continuous circumferential welding, realizing full automation from load-bearing idler loading to welding completion, greatly reducing manual intervention and lifting times. The symmetrically arranged welding component 109 supports simultaneous welding at both ends, significantly improving efficiency. The collaborative operation of each functional module ensures high precision and high stability in the welding process.

[0026] The entire device also includes a control system and an industrial camera module. Each structure is controlled by the control system, and the industrial camera module includes a vision acquisition unit, an image processing unit, and a signal interaction module.

[0027] The visual acquisition unit includes four industrial high-speed cameras. Two of these are close-up cameras for the welding area, symmetrically mounted next to the welding torches of the two welding components 109 (maintaining a distance of 15-20cm from the welding torches, with the lenses facing the weld pool area), used to capture the molten pool morphology and weld formation status in real time. The other two are overall roller monitoring cameras, respectively mounted above both ends of the support and clamping components, with lenses covering the entire length of the rollers, used to monitor the roller rotation stability, axial movement, and overall welding progress. All cameras are equipped with high-brightness, anti-interference LED supplementary lights to avoid interference from welding arc light and spatter on image acquisition, ensuring image clarity in low-light and high-interference environments.

[0028] The image processing unit incorporates a high-performance industrial control host and is equipped with dedicated machine vision algorithms (including molten pool feature recognition algorithm, weld edge extraction algorithm, defect detection algorithm, and rotation state analysis algorithm). This unit can process real-time images captured by the camera at high speed, extract key feature parameters such as molten pool size, molten depth trend, weld width, spatter amount, and idler roller rotation angular velocity, and compare them with preset standard parameter thresholds to determine whether the welding state is normal.

[0029] The signal interaction module adopts a dual signal transmission method of industrial Ethernet + PLC linkage. One end communicates with the vision acquisition unit to receive image data; the other end interacts bidirectionally with the control system, transmitting the status judgment results and parameter adjustment instructions after image processing to the main control system. At the same time, it receives the device operation parameters (such as current welding current, voltage, welding torch position, roller rotation speed, etc.) fed back by the main control system to achieve information synchronization.

[0030] The vision camera module participates in the entire process of idler roller welding, from preheating to welding and finishing. It achieves closed-loop control through real-time monitoring and dynamic adjustment. The specific workflow is as follows: 1. Preheating stage before welding: reference calibration and parameter preset After the load-bearing idler roller is positioned by the support clamping assembly 2 and clamped by the follow-up translation assembly 3 and the rotation drive assembly 1, the vision camera module is activated in advance. The overall monitoring camera of the idler roller captures an image of the entire length of the idler roller, and determines the precise position of the welding positions at both ends of the idler roller through image recognition. The position information is fed back to the main control system, and the welding gun of the welding assembly 109 is adjusted to align with the starting point of the welding, completing the welding gun positioning calibration. At the same time, the image processing unit calls up the preset welding standard parameter library (matching the corresponding standard molten pool size, weld width, rotation speed and other parameters according to the idler roller material, diameter, wall thickness) as the benchmark threshold for subsequent monitoring and adjustment.

[0031] 2. During the welding process: Real-time monitoring and dynamic adjustment After welding is initiated, the vision camera module enters real-time operation, primarily implementing two monitoring and adjustment functions: (1) Welding quality monitoring and welding parameter adjustment: The close-up camera in the welding area captures images of the molten pool and weld at a rate of 30 frames per second. The image processing unit extracts characteristic parameters such as the area of ​​the molten pool, the brightness of the molten pool, the smoothness of the weld edge, and the size and quantity of spatter particles in real time. If the molten pool is detected to be too large (exceeding the standard threshold by 15%), it is judged that the welding current is too high, and an adjustment command is immediately sent to the control system to reduce the welding current; if the molten pool is too small or the weld edge is discontinuous, the welding voltage is increased or the welding torch movement speed is slowed down; if there is too much spatter, it is judged that the shielding gas is insufficient or the gas flow is unstable, and the shielding gas flow rate is adjusted. The response time of the entire adjustment process is ≤0.5 seconds, ensuring real-time correction of welding quality.

[0032] (2) Monitoring and adjustment of roller rotation status: The overall monitoring camera tracks the roller rotation trajectory in real time, calculates the actual rotational angular velocity of the roller by the image frame difference method, and identifies whether there is axial movement of the roller (monitoring the relative position change between the roller end and the clamping part). If the rotational speed fluctuation is detected (the deviation exceeds the standard speed ±5%), a speed calibration command is sent to the rotation drive component to adjust the servo motor speed to ensure that the roller rotates at a uniform speed; if axial movement is found (movement > 0.5mm), the follow-up translation component 3 is immediately instructed to fine adjust the clamping force, and welding is paused. Welding is resumed after the movement is eliminated to avoid weld offset due to movement.

[0033] 3. Welding Finishing Stage: Quality Verification and Optimization of Finishing Parameters As welding nears completion (judged by the number of roller rotations and welding time), the vision camera module intensifies monitoring of the weld finishing area. The image processing unit compares the weld quality of the finishing area with that of the intermediate area. If it detects that the weld at the finishing point has widened or narrowed, it instructs the welding current to gradually decrease (the current decays smoothly during the finishing stage), while simultaneously slowing down the roller rotation speed to ensure a smooth transition between the finishing weld and the overall weld. After welding is completed, the vision camera module acquires complete images of the welds at both ends, generating a preliminary weld quality inspection report. This report marks the presence of obvious defects such as incomplete penetration, porosity, and cracks, providing a reference for subsequent quality spot checks.

[0034] The settings for the vision camera module have the following effects: 1. Improve welding quality stability: Through real-time monitoring and dynamic parameter adjustment, it effectively solves defects such as uneven penetration, weld offset, and excessive spatter caused by fixed parameters in traditional welding, and the welding qualification rate can be improved by 8%-12%.

[0035] 2. Enhanced flexibility in adapting to multiple specifications: Visual recognition can automatically adapt to rollers of different diameters and lengths, eliminating the need for manual recalibration of welding gun positions and welding parameters, thus improving changeover efficiency by more than 60%.

[0036] 3. Reduce reliance on manual labor and labor intensity: Replace manual visual monitoring of welding status, reduce manual intervention, and avoid operators directly facing harsh environments such as welding arc light, thereby improving production safety.

[0037] 4. Enable welding data traceability: It can record the welding process images and parameter adjustment trajectory of each idler roller, generate quality inspection reports, and facilitate production quality traceability and process optimization.

[0038] Reference Figures 8-10The support mechanism includes two support groups spaced apart along the length of the load-bearing idler. Each support group includes a bracket 201 and a first roller group 202 arranged in a V-shape on the bracket 201. The first roller group 202 is arranged perpendicular to the length of the load-bearing idler.

[0039] Specifically, the bracket 201 is a support with an approximate U-shape, with its two legs offset outwards. The first roller group 202 has two rollers, which are respectively positioned on the two legs of the U-shaped bracket, thus forming a V-shaped channel. The two V-shaped roller groups of the two support groups form two-point support. The V-shaped channel structure can naturally guide and initially position the cylindrical idler in the radial direction, providing stable and reliable support and ensuring smooth axial movement of the load-bearing idler (i.e., rolling between the two first roller groups 202). The V-shaped surface has a self-centering function, facilitating the rapid placement and initial centering of the load-bearing idler. The roller structure reduces friction with the load-bearing idler, facilitating fine-tuning of the load-bearing idler before clamping and subsequent rotational drive.

[0040] Reference Figure 10 The lifting mechanism includes two lifting parts 205 disposed at the bottom of the corresponding bracket 201. Each lifting part 205 includes a chassis 205a, a rotating cylinder 205b rotatably connected to the chassis 205a, a threaded rod 205c threadedly connected to the rotating cylinder 205b, and a mounting head 205d disposed at the top of the threaded rod 205c. The end of the mounting head 205d away from the threaded rod 205c is connected to the bracket 201.

[0041] During the lifting and adjustment process, the user rotates the rotating cylinder 205b, which engages with the threaded rod 205c, causing the threaded rod 205c to move up and down. This drives the bracket 201 and the two sets of first roller groups 202 above to move up and down together, achieving independent and precise fine-tuning of the center height of the load-bearing roller. The structure is simple, has good self-locking properties, and can ensure that the support height remains stable during the welding process.

[0042] The lifting unit 205 also includes a first guide unit 204, which includes a guide cylinder 204a and a guide rod 204b arranged side by side with the chassis 205a. The two form a vertical sliding fit. The first guide unit 204 provides guidance for the lifting adjustment of the lifting mechanism, eliminates the lateral sway or rotation that may occur during the lifting process, and ensures that the bracket 201 and the load-bearing roller only make pure vertical movements, thereby improving the accuracy and stability of self-alignment.

[0043] Specifically, the mounting head 205d is a T-shaped block, and the bottom of the bracket 201 is provided with a T-shaped mounting port 203. The T-shaped block and the T-shaped mounting port 203 are matched and then fixed by bolts.

[0044] Furthermore, to further enhance the automation of the device, the lifting unit 205 can also adopt an automatic lifting structure, such as a linear drive structure like a cylinder or hydraulic cylinder.

[0045] Reference Figure 9 The elastic clamping mechanism includes two elastic clamping parts disposed at the first and second ends of two brackets 201. The two elastic clamping parts are symmetrical about the load-bearing roller axis. Each elastic clamping part includes a transverse shaft 206 rotatably connected between the first or second ends of the two brackets 201, a linkage 207 disposed on the transverse shaft 206, a second connecting part 2010 disposed on the linkage 207 and inclined upward, a swing frame 2011 rotatably disposed on the second connecting part 2010, a second roller 2012 rotatably connected to the swing frame 2011, and an elastic element 2014 connecting the two swing frames 2011. The second roller 2012 is arranged in the same direction as the length direction of the load-bearing roller. The swing frame 2011 is relatively squeezed and clamped by the elastic element 2014.

[0046] When the load-bearing idler is placed into the support mechanism, its own weight presses down on the second roller 2012, forcing the swing frames 2011 on both sides to swing outward around the hinge point of the second connecting part 2010, stretching the elastic element 2014; the restoring force generated by the elastic element 2014 is transmitted to the second roller 2012 through the swing frame 2011, causing it to press the side wall of the load-bearing idler from both sides inward, forming an adaptive clamping, realizing the rapid and automatic clamping of the load-bearing idler without the need for an external power source and complex operation. The elastic clamping force can adapt to the diameter change of the load-bearing idler within a certain range, and avoids the surface damage of the load-bearing idler that may be caused by rigid clamping.

[0047] Preferably, the elastic clamping mechanism further includes a second guide portion that guides the clamping movement of the two elastic clamping parts. The second guide portion includes two first connecting portions 208 disposed on the bottom side of the two linkage members 207 and two telescopic rods 209 disposed at the ends of the two first connecting portions 208 away from the linkage members 207. The opposite ends of the two telescopic rods 209 are movably inserted into the connecting cylinder 2091. When the linkage member 207 rotates due to the downward pressure of the load-bearing roller, the first connecting portions 208 drive the telescopic rods 209 to move synchronously within the connecting cylinder 2091, ensuring that the clamping components on both sides of the load-bearing roller open and close strictly synchronously and symmetrically, preventing clamping skew or failure caused by unilateral jamming, and improving the reliability and repeatability of the clamping action.

[0048] Preferably, the elastic clamping mechanism further includes a load-bearing frame 2013 disposed between the two brackets 201. The top surface of the load-bearing frame 2013 is arc-shaped, conforming to the cross-section of the load-bearing idler. The elastic element 2014 passes through the bottom of the load-bearing frame 2013. This arrangement rationally positions the elastic element 2014, preventing it from affecting the load-bearing idler. For longer load-bearing idlers, the arc-shaped surface of the load-bearing frame 2013 provides auxiliary support in the middle, sharing the main weight. The elastic element 2014 is disposed in the space below it, effectively preventing excessive deflection deformation of the long load-bearing idler due to its own weight, ensuring welding straightness. The arc-shaped support surface avoids interference with the load-bearing idler and optimizes the structural layout, making the installation of the elastic element 2014 more compact and safe.

[0049] Preferably, the rotary drive assembly 1 includes a servo motor 101 and a reducer 102 that are drivenly connected to the servo motor 101, a reduction mechanism that is drivenly connected to the reducer 102, and a first clamping part that is drivenly connected to the reduction mechanism. The first clamping part abuts against one end of the load-bearing roller.

[0050] The servo motor 101 provides precise and controllable rotational power. After initial reduction and torque increase by the reducer 102, it is transmitted to the first clamping part through the reduction mechanism, driving it to rotate together with the clamped load-bearing roller. The two-stage reduction structure ensures that the roller is more stable during rotation.

[0051] Preferably, the reduction mechanism includes a drive shaft 1013 connected to the reducer, a second gear 1014 mounted on the drive shaft 1013, a first gear 1012 meshing with the second gear 1014, and a rotating body 103 connected to the first gear 1012. One end of the rotating body 103 away from the first gear 1012 is connected to a first clamping part. Power is input from the drive shaft 1013, and the reduction and change of transmission direction are achieved through the meshing of the second gear 1014 with the first gear 1012, ultimately driving the rotating body 103 and the first clamping part to rotate. This secondary reduction using a gear pair further increases the output torque, meeting the driving force requirements for the rotation of heavy-duty load-bearing rollers. The gear transmission is smooth, the structure is compact, and it is easy to arrange in a limited space.

[0052] Specifically, the rotary drive assembly 1 also includes a housing 104, a rotating body 103, a seal 107, a bearing 1010, a connector 1012, and a rear cover 1016. The first tightening part includes a threaded cylinder 108, a first tightening head 105, and a locking nut 106.

[0053] The outer shell 104 is fixedly mounted on the workbench 100. The outer shell 104 has a first cavity a and a second cavity b located on one side of the first cavity a and communicating with the first cavity a. The rotating body 103 is rotatably mounted in the first cavity a via a bearing 1010. A sealing element 107, which is a sealing ring, is installed on the outer shell 104 at a position where the rotating body 103 extends from its front end. The sealing element 107 is a sealing ring that is sealed to the outer shell 104. A threaded cylinder 108 is fixedly connected to the front end of the rotating body 103. A first tightening head 105 is threadedly mounted on the front end of the threaded cylinder 108. A locking device for locking the threaded cylinder 108 and the first tightening head 105 is threaded on the first tightening head 105. The locking nut 106 is used to secure the rear end of the rotating body 103 to the connecting body 1011 via the locking screw 1015. The first gear 1012 is key-fitted onto the outside of the connecting body 1011. The front end of the second cavity b is closed, and the drive shaft 1013 is rotatably mounted towards the rear end. The second gear 1014 is key-fitted onto the drive shaft 1013. A rear cover 1016 is fixedly mounted at the rear end of the outer shell 104, covering the rear ends of the first cavity a and the second cavity b. One end of the drive shaft 1013 passes through a pre-drilled hole in the rear cover 1016, and the rear end of the drive shaft 1013 is set as a splined shaft, which is connected to the reducer 102 for transmission.

[0054] During operation, the servo motor 101 drives the reducer 102. After the first stage of reduction by the reducer 102, it drives the transmission shaft 1013 to rotate. The transmission shaft 1013 drives the second gear 1014 to rotate, and the second gear 1014 drives the first gear 1012 to rotate. At this time, the second stage of reduction is performed. Then, the connecting body 1011, the rotating body 103, the threaded cylinder 108 and the first clamping head 105 are driven to rotate. The secondary reduction is achieved by using the gear pair, which can further increase the output torque and meet the driving force requirements of the heavy-duty load-bearing roller rotation. The gear transmission is smooth, the structure is compact, and it is easy to arrange in a limited space.

[0055] Preferably, the follower translation component 3 includes a base 301, a slide rail disposed on the base 301, a slider 302 slidably connected to the slide rail, a linear drive unit 304 disposed on the base 301, and a second clamping unit rotatably connected to the slider 302. The linear drive unit 304 drives the slider 302 to move linearly toward the support clamping component 2 until the second clamping unit cooperates with the rotary drive component 1 to clamp the load-bearing idler. The linear drive unit 304 (such as a cylinder, hydraulic cylinder, electric push rod, or gear rack pair) serves as a power source, pushing the slider 302 to move linearly along the slide rail, driving the second clamping unit on it to move forward until it contacts the tail end of the load-bearing idler and applies a predetermined clamping force, providing a stable and adjustable axial clamping force. Together with the rotary drive component 1, it constitutes a reliable drive-clamping system for the rotation of the load-bearing idler. The slide rail guide ensures the linear accuracy of the clamping movement, thereby ensuring the final alignment quality of the load-bearing idler.

[0056] The second tightening part includes a tightening rod and a second tightening head 303. One end of the tightening rod is rotatably connected to the sliding body 302, and the other end is connected to the second tightening head 303.

[0057] In addition, a sub-frame 305 is provided on the outside of the sliding body 302, and a welding assembly 109 is mounted on the sub-frame 305. The welding assembly 109 includes a mounting bracket and a welding torch. The sub-frame 305 serves as a mounting bracket for the welding assembly 109, and the welding torch on the mounting bracket is labeled H2. Another mounting bracket for the welding assembly 109 is provided on the worktable 100, and the welding torch on the mounting bracket is labeled H1.

[0058] In use, the user pre-assembles the end caps onto both ends of the cylindrical structure to form the load-bearing idler roller to be welded. Then, the load-bearing idler roller is placed between the two sets of first roller groups 202 on the support clamping assembly 2. The telescopic rod 209 extends, and the two first connecting parts 208 are unrestrained. Under the elastic force of the elastic element 2014, the linkages 207 on both sides rotate outward, causing the second roller 2012 to press the load-bearing idler roller inward, ensuring accurate positioning of the load-bearing idler roller. The linear drive unit 304 actuates, pushing the sliding body 302 and the second clamping head 303 towards the central region. The second clamping head 303 pushes the first end of the load-bearing idler roller, causing the load-bearing idler roller to slide axially on the two sets of first roller groups 202. The second end abuts against the end of the first clamping head 105, and then drives the servo motor 101 to perform welding operations synchronously. The servo motor 101 drives the reducer 102. After the first stage of reduction by the reducer 102, the drive shaft 1013 is driven to rotate. The drive shaft 1013 drives the second gear 1014 to rotate. The second gear 1014 drives the first gear 1012 to rotate. At this time, the second stage of reduction is performed. Then the connecting body 1011, the rotating body 103, the threaded cylinder 108 and the first clamping head 105 are driven to rotate. The first clamping head 105 drives the load-bearing roller to rotate. The load-bearing roller drives the second clamping head 303 to rotate. The rotation of the load-bearing roller, together with the welding guns H2 and H1, completes the welding operation using CO2 gas shielded welding.

[0059] On the other hand, this embodiment also discloses a method for using the above-mentioned automated load-bearing idler welding device, including the following steps: Place the load-bearing idler roller to be welded on the support mechanism. At this time, the elastic clamping mechanism clamps the load-bearing idler roller under its elastic action. The lifting mechanism adjusts the height of the load-bearing roller so that the load-bearing roller, the first clamping part of the rotary drive assembly 1, and the second clamping part of the follow-up translation assembly 3 are coaxial. The follow-up translation component 3 moves toward the load-bearing idler roller so that the first clamping part and the second clamping part clamp the load-bearing idler roller; The welding assembly 109 is activated to weld the position to be welded on the load-bearing idler. During the welding process, the rotation drive assembly 1 drives the load-bearing idler to rotate for rotational welding.

[0060] First, an elastic mechanism achieves automatic initial clamping and radial positioning; then, a lifting and leveling mechanism achieves pre-alignment of the axis; finally, axial clamping completes precise centering and rigid fixation; and finally, welding is completed in a rotating state. This operation method has clear steps and a high degree of automation, greatly reducing the skill requirements and labor intensity of operators. Each step serves the final welding accuracy and quality, ensuring the controllability of the process and the consistency of the results.

[0061] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solutions of the present invention, and these simple modifications all fall within the protection scope of the present invention. Furthermore, it should be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the present invention will not further describe the various possible combinations.

[0062] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. An automated load-bearing idler roller welding device, characterized in that, It includes a rotary drive assembly, a support clamping assembly, a follow-up translation assembly arranged side by side in the same direction, and two welding assemblies located at both ends of the support clamping assembly for welding the load-bearing idler roller; The support and clamping assembly includes a lifting mechanism, a support mechanism disposed on the lifting mechanism, and an elastic clamping mechanism disposed on the support mechanism. When the load-bearing roller is placed on the support mechanism, the elastic clamping mechanism automatically clamps the side wall of the load-bearing roller by its own elastic force. The lifting mechanism is used to drive the support mechanism and the clamping mechanism to move up and down. The follower translation component can move linearly relative to the support clamping component. During the movement, the follower translation component cooperates with the rotary drive component to clamp both ends of the load-bearing roller. The rotary drive component can drive the load-bearing roller to rotate.

2. The automated load-bearing idler roller welding device according to claim 1, characterized in that, The support mechanism includes two support groups spaced apart along the length of the load-bearing idler roller. Each support group includes a bracket and a first idler roller group arranged in a V-shape on the bracket. The arrangement direction of the first idler roller group is perpendicular to the length direction of the load-bearing idler roller.

3. The automated load-bearing idler roller welding device according to claim 2, characterized in that, The lifting mechanism includes two lifting parts disposed at the bottom of the corresponding bracket. Each lifting part includes a chassis, a rotating cylinder rotatably connected to the chassis, a threaded rod threadedly connected to the rotating cylinder, and a mounting head disposed at the top of the threaded rod. The end of the mounting head away from the threaded rod is connected to the bracket.

4. The automated load-bearing idler roller welding device according to claim 2, characterized in that, The elastic clamping mechanism includes two elastic clamping parts disposed at the first and second ends of the two brackets. The two elastic clamping parts are symmetrical about the load-bearing roller axis. Each elastic clamping part includes a transverse shaft rotatably connected between the first or second ends of the two brackets, a linkage member disposed on the transverse shaft, a second connecting part disposed on the linkage member and inclined upward, a swing frame rotatably disposed on the second connecting part, a second roller rotatably connected to the swing frame, and an elastic member connecting the two swing frames. The second roller is arranged in the same direction as the length direction of the load-bearing roller. The swing frames are relatively squeezed and clamped by the elastic member.

5. The automated load-bearing idler roller welding device according to claim 4, characterized in that, The elastic clamping mechanism further includes a second guide portion that provides guidance for the clamping movement of the two elastic clamping parts. The second guide portion includes two first connecting portions disposed on the bottom side of the two linkage members and two telescopic rods disposed on the ends of the two first connecting portions away from the linkage members. The opposite ends of the two telescopic rods are movably inserted into the connecting cylinder.

6. The automated load-bearing idler roller welding device according to claim 4, characterized in that, The elastic clamping mechanism also includes a load-bearing frame disposed between the two brackets, the top surface of the load-bearing frame being arc-shaped to match the cross-section of the load-bearing roller, and the elastic element passing through the bottom of the load-bearing frame.

7. The automated load-bearing idler roller welding device according to claim 1, characterized in that, The rotary drive assembly includes a servo motor and a reducer that are driven by the servo motor, a reduction mechanism that is driven by the reducer, and a first clamping part that is driven by the reduction mechanism. The first clamping part abuts against one end of the load-bearing roller.

8. The automated load-bearing idler roller welding device according to claim 7, characterized in that, The deceleration mechanism includes a drive shaft that is connected to the reducer, a second gear disposed on the drive shaft, a first gear that meshes with the second gear, and a rotating body connected to the first gear. The end of the rotating body away from the first gear is connected to the first clamping part.

9. The automated load-bearing idler roller welding device according to claim 1, characterized in that, The follow-up translation component includes a base, a slide rail disposed on the base, a slider slidably connected to the slide rail, a linear drive unit disposed on the base, and a second clamping unit disposed on the slider. The linear drive unit is used to drive the slider to move linearly toward the support clamping component until the second clamping unit cooperates with the rotary drive component to clamp the load-bearing roller.

10. A method of using the automated load-bearing idler roller welding device according to any one of claims 1-9, characterized in that, Includes the following steps: Place the load-bearing idler roller to be welded on the support mechanism. At this time, the elastic clamping mechanism clamps the load-bearing idler roller under its elastic action. The lifting mechanism adjusts the height of the load-bearing roller so that the load-bearing roller, the first clamping part of the rotary drive assembly, and the second clamping part of the follow-up translation assembly are coaxial. The follow-up translation component moves toward the load-bearing idler roller, causing the first clamping part and the second clamping part to clamp the load-bearing idler roller together; The welding assembly is activated to weld the position to be welded on the load-bearing idler. During the welding process, the rotation drive assembly drives the load-bearing idler to rotate for welding.

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