Production and manufacturing welding device for power distribution switch assembly

Abstract

The invention provides a production and manufacturing welding device for a power distribution switch assembly, and relates to the technical field of production and manufacturing of power distribution switches. The production and manufacturing welding device for the power distribution switch assembly comprises a workbench, a rotary welding table, a power distribution switch assembly pushing structure, a three-dimensional adjustable welding mechanism, an intelligent temperature control heat dissipation system, a visual positioning detection system and a central control system. The rotating welding table is driven by a rotating motor to rotate, and a plurality of power distribution switch assembly pushing structures are evenly arranged on the periphery of the rotating welding table along the circle. Compared with existing traditional welding equipment, the automation degree is higher, the rotary welding table is matched with the power distribution switch assembly pushing structure, multiple power distribution switch assemblies can be sequentially pushed to the rotary welding table at a time, and therefore the multiple power distribution switch assemblies can be automatically welded, and whole-process continuous operation is achieved.

Description

Technical Field

[0001] This invention relates to the field of power distribution switch manufacturing technology, specifically to a welding apparatus for the production and manufacturing of power distribution switch components. Background Technology

[0002] As the core control equipment of the power system, the welding quality of the components of the distribution switch directly affects the insulation performance, structural stability and service life of the equipment. The existing welding devices for distribution switch components have the following technical defects: insufficient positioning accuracy. Traditional devices mostly use single-view visual positioning or manual marking positioning. The conversion error from two-dimensional image to three-dimensional coordinate is large, which makes it difficult to meet the requirements for precise control of insulation gap. This can easily lead to welding deviation and cause short circuit hazards. At the same time, the control of thermal deformation is not good. Uneven heat input during the welding process can easily cause local overheating and deformation of metal components, affecting the accuracy of subsequent assembly.

[0003] Therefore, this invention proposes a welding device for power distribution switch components with high-precision positioning, low thermal deformation, multi-specification adaptability, and full-process automation, thereby effectively solving the above-mentioned problems and difficulties. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a welding apparatus for manufacturing power distribution switch components, which enables high-precision positioning welding, effectively controls thermal deformation, adapts to various specifications of power distribution switch components, and improves the automation level and production efficiency of the welding process.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A welding apparatus for manufacturing power distribution switch components includes a workbench, a rotating welding table, a power distribution switch component pushing structure, a three-dimensional adjustable welding mechanism, an intelligent temperature control and heat dissipation system, a visual positioning and detection system, and a central control system. A rotating welding table is installed on the workbench and is driven to rotate by a rotating motor. Multiple power distribution switch component pushing structures are evenly arranged around the periphery of the rotating welding table. Each power distribution switch component pushing structure is used to push the power distribution switch component to be processed onto the rotating welding table for welding processing. The main body of the three-dimensional adjustable welding mechanism is a three-dimensional robotic arm, which is rotatably mounted on the worktable. The machining end of the three-dimensional robotic arm is equipped with a laser welding head and a vision positioning and detection camera. The laser welding head integrates a welding parameter adjustment module, which can adaptively adjust the laser power, welding speed and spot size according to the welding material and thickness. The intelligent temperature control and heat dissipation system includes an infrared temperature sensor, a cooling airflow jet assembly, and a water-cooling circulation assembly. The infrared temperature sensor is installed on the side of the laser welding head. The cooling airflow jet assembly includes an annular jet nozzle, which is coaxially sleeved on the outside of the laser welding head. The start, stop, and flow rate of the cooling airflow are controlled by a solenoid valve. The water-cooling circulation assembly includes a cooling water tank, a circulating water pump, and a water-cooling fixture. The water-cooling fixture is embedded in the positioning base and forms a circulation loop with the cooling water tank through pipes. The central control system is electrically connected to the rotating welding table, the power distribution switch component pushing structure, the three-dimensional adjustable welding mechanism, the intelligent temperature control and heat dissipation system, and the visual positioning and detection system. The central control system has built-in positioning coordinate correction algorithm, incremental PID intelligent temperature control algorithm, and welding parameter adaptive algorithm. The positioning coordinate correction algorithm is used to convert the two-dimensional image coordinates collected by the visual positioning and detection system into the actual three-dimensional coordinates of the welding target point. The incremental PID intelligent temperature control algorithm is used to adjust the cooling airflow and water cooling circulation rate to stabilize the temperature of the welding area. The welding parameter adaptive algorithm is used to match the laser power and welding speed according to the material, thickness, and thermal conductivity of the power distribution switch component. Through the above technical solutions, the entire equipment achieves fully automated operation from component loading, positioning, welding, temperature control to inspection. The three-dimensional adjustable welding mechanism combined with visual positioning technology greatly improves welding positioning accuracy, the intelligent temperature control system effectively suppresses thermal deformation, and the welding parameter adaptive algorithm ensures the welding quality stability of components of different specifications, significantly improving production efficiency and product qualification rate.

[0006] Furthermore, a liftable robotic arm is provided on the top of the workbench, and a dust cleaning device is installed at the output end of the liftable robotic arm. The dust cleaning device is a high-power vacuum cleaner located on the top of the rotating welding table, which vacuums and cleans the power distribution switch assembly before the welding process. The above technical solution allows for targeted dust cleaning of the component welding area before welding, preventing defects such as weld inclusions and porosity caused by impurities and dust residue, ensuring the mechanical and insulation properties of the welded joint, and laying the foundation for subsequent high-precision welding.

[0007] Furthermore, each of the power distribution switch assembly push structures includes a positioning base, an adjustable positioning pin, a pneumatic clamping assembly, and a pressure sensor. The adjustable positioning pin fixes the power distribution switch with locking bolts. The pneumatic clamping assembly is symmetrically arranged on both sides of the positioning base, and an elastic pressure head is installed at the output end to push the power distribution switch assembly to the rotating welding table. The pressure sensor is integrated into the elastic pressure head. Through the above technical solutions, the adjustable positioning pin can be adapted to power distribution switch components of different sizes and specifications, improving the versatility of the equipment; the pneumatic clamping component, together with the elastic pressure head, can achieve stable clamping and pushing of the component, avoiding mechanical damage; the pressure sensor monitors the clamping pressure in real time to ensure that the pressure is within the preset safe range, which not only ensures the positioning stability of the component, but also prevents the component from deforming due to excessive clamping.

[0008] Furthermore, one side of the workbench is equipped with a qualified product conveyor line and a non-qualified product collection box. The central control system reminds the staff to classify and place qualified and non-qualified products according to the judgment results of the inspection station. The above technical solutions enable automated sorting of welding products, avoiding the mixing of qualified and unqualified products, reducing manual sorting errors, and facilitating centralized processing and quality traceability of unqualified products, thereby improving the standardization of production management.

[0009] Furthermore, the positioning coordinate correction algorithm of the central control system combines the two-dimensional image information acquired by the visual positioning detection camera with the camera calibration parameters to complete the three-dimensional coordinate transformation. The coordinate correction algorithm eliminates the influence of installation errors and image distortion, obtaining the accurate actual coordinates of the welding target point. The algorithm formula is as follows: ; in The actual three-dimensional coordinates of the welding target point; To locate the target point in the image acquired by the camera; The initial height of the target point calibrated for the camera; The focal length of the camera; This is the correction amount for equipment installation errors; The above technical solution accurately converts two-dimensional image coordinates into actual three-dimensional welding coordinates, effectively offsetting positioning errors caused by factors such as camera installation deviation and image distortion. This significantly improves the positioning accuracy of welding target points, meeting the high-precision requirements of insulation gaps and structural dimensions of power distribution switch components, and preventing short-circuit hazards caused by welding deviations from the source.

[0010] Furthermore, the intelligent temperature control PID algorithm of the central control system uses an incremental PID control algorithm to adjust the cooling airflow and water cooling circulation rate, so that the temperature of the welding area is stabilized within a preset threshold range, suppressing thermal deformation. Its calculation formula is as follows: ; ; in, This represents the increment of cooling airflow or cooling water flow corresponding to the k-th sample. This is the proportionality coefficient; The integral coefficient; These are the differential coefficients; The temperature deviation of the k-th sample; , To preset the temperature threshold, The actual welding temperature during the k-th sampling; This is the final control value for the k-th sample. This is the control quantity for the (k-1)th sample; Through the above technical solutions, the incremental PID algorithm has a fast response speed and high adjustment accuracy. It can dynamically adjust the heat dissipation intensity according to the real-time changes in welding temperature, so that the temperature of the welding area is stabilized at the preset threshold. This effectively suppresses the local overheating deformation of metal components caused by uneven heat input, and ensures the dimensional accuracy and assembly compatibility of the components after welding.

[0011] Furthermore, the adaptive algorithm for welding parameters in the central control system is based on the material of the power distribution switch assembly ( ),thickness( ) and thermal conductivity ( Adaptive matching laser power ( ) and welding speed ( To ensure the weld penetration meets the standard and there is no excessive burn-off, the calculation formula is as follows: ; in This is a process correction factor, obtained by fitting historical qualified welding data from a parameter database, with a range of [range missing]. , ; For the density of the welding material, The thickness of the component weld joint. For the thermal conductivity of the material, For laser welding power, For welding speed; Through the above technical solution, the algorithm realizes intelligent matching of welding parameters based on the core physical parameters of the components, eliminating the need for repeated manual adjustments. This ensures that the weld penetration meets the strength requirements while avoiding excessive burning or incomplete penetration caused by improper parameters, thus significantly improving the welding adaptability and quality consistency of components of different specifications and materials.

[0012] This invention provides a welding apparatus for manufacturing power distribution switch assemblies. It has the following advantages: 1. This invention provides a welding device for the production and manufacturing of power distribution switch components. Compared with existing traditional welding equipment, it has a higher degree of automation. The rotating welding table and the power distribution switch component pushing structure can push multiple power distribution switch components onto the rotating welding table in sequence at one time, thereby automatically welding multiple power distribution switch components and realizing continuous operation throughout the entire process. The central control system coordinates the coordinated actions of various mechanisms through three core algorithms, reduces manual intervention, improves production efficiency, and ensures the consistency of welding quality.

[0013] 2. This invention provides a welding device for the production and manufacturing of power distribution switch components. Compared with traditional welding equipment, the intelligent temperature control and heat dissipation system, combined with an incremental PID algorithm, monitors the welding temperature in real time through infrared temperature measurement. It coordinates cooling air jet and water cooling circulation for dual heat dissipation, precisely adjusts the heat dissipation intensity, effectively controls the temperature field distribution in the welding area, reduces the thermal deformation of metal components, and improves the subsequent assembly accuracy. Furthermore, through the synergistic effect of a visual positioning detection system and a three-dimensional adjustable welding mechanism, combined with a positioning coordinate correction algorithm and grating ruler positioning feedback, it achieves precise control of the welding position with a positioning accuracy of ±0.01mm, effectively avoiding welding deviations and ensuring the insulation performance and connection reliability of the power distribution switch components. Attached Figure Description

[0014] Figure 1 This is a structural functional framework diagram of the welding apparatus for manufacturing the power distribution switch assembly of the present invention; Figure 2 This is a flowchart of the welding process steps of the welding device for manufacturing the power distribution switch assembly of the present invention. Figure 3 A schematic diagram showing the overall effect of the welding apparatus for manufacturing the power distribution switch assembly of the present invention; Figure 4 This is a schematic diagram of the rotating welding table of the welding apparatus for manufacturing the power distribution switch assembly of the present invention.

[0015] In the picture: 1. Workbench; 2. Central control system; 3. Liftable robotic arm; 4. Dust cleaning equipment; 5. Power distribution switch assembly pushing structure; 6. Rotating welding table; 7. Three-dimensional robotic arm; 8. Rotating motor; 9. Rotating shaft. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Example 1: like Figure 1-4 As shown, this embodiment of the invention provides a welding device for manufacturing power distribution switch components, including a workbench (1), a rotating welding table (6), a power distribution switch component pushing structure (5), a three-dimensional adjustable welding mechanism, an intelligent temperature control and heat dissipation system, a visual positioning and detection system, and a central control system (2). A rotating welding table is installed on the workbench, and the rotating welding table is driven to rotate by a rotating motor. Multiple power distribution switch component pushing structures (5) are evenly arranged around the outer periphery of the rotating welding table (6). Each power distribution switch component pushing structure (5) is used to push the power distribution switch component to be processed onto the rotating welding table (6) for welding processing. The main body of the three-dimensional adjustable welding mechanism is a three-dimensional robotic arm (7). The three-dimensional robotic arm is rotated and set on the worktable (1). The machining end of the three-dimensional robotic arm (7) is equipped with a laser welding head and a vision positioning and detection camera. The laser welding head is integrated with a welding parameter adjustment module, which can adaptively adjust the laser power, welding speed and spot size according to the welding material and thickness. The intelligent temperature control and heat dissipation system includes an infrared temperature sensor, a cooling air jet assembly, and a water cooling circulation assembly. The infrared temperature sensor is installed on the side of the laser welding head. The cooling air jet assembly includes an annular jet nozzle, which is coaxially sleeved on the outside of the laser welding head. The start, stop, and flow rate of the cooling air are controlled by a solenoid valve. The water cooling circulation assembly includes a cooling water tank, a circulating water pump, and a water cooling fixture. The water cooling fixture is embedded in the positioning base and forms a circulation loop with the cooling water tank through pipes. The central control system (2) is electrically connected to the rotating welding table (6), the power distribution switch assembly push structure (5), the three-dimensional adjustable welding mechanism, the intelligent temperature control and heat dissipation system, and the visual positioning and detection system. The central control system (2) has a built-in positioning coordinate correction algorithm, an incremental PID intelligent temperature control algorithm, and a welding parameter adaptive algorithm. The positioning coordinate correction algorithm is used to convert the two-dimensional image coordinates collected by the visual positioning and detection system into the actual three-dimensional coordinates of the welding target. The incremental PID intelligent temperature control algorithm is used to adjust the cooling airflow and water cooling circulation rate to stabilize the temperature of the welding area. The welding parameter adaptive algorithm is used to match the laser power and welding speed according to the material, thickness, and thermal conductivity of the power distribution switch assembly.

[0018] Example 2: like Figure 1-4 As shown, this embodiment of the invention provides a welding device for manufacturing power distribution switch components. A liftable mechanical arm (3) is provided on the top of the workbench (1). A dust cleaning device (4) is installed at the output end of the liftable mechanical arm (3). The dust cleaning device (4) is a high-power dust collection device located on the top of the rotating welding table. It performs dust collection and cleaning on the power distribution switch components before the welding process. Each of the power distribution switch assembly push structures (5) includes a positioning base, an adjustable positioning pin, a pneumatic clamping assembly and a pressure sensor. The adjustable positioning pin fixes the power distribution switch by locking bolts. The pneumatic clamping assembly is symmetrically arranged on both sides of the positioning base. An elastic pressure head is installed at the output end to push the power distribution switch assembly to the rotating welding table. The pressure sensor is integrated into the elastic pressure head. One side of the workbench (1) is equipped with a qualified product conveyor line and a non-qualified product collection box. The central control system reminds the staff to classify and place qualified and non-qualified products according to the judgment results of the inspection station. The positioning coordinate correction algorithm of the central control system (2) combines the two-dimensional image information collected by the visual positioning detection camera with the camera calibration parameters to complete the three-dimensional coordinate transformation. The coordinate correction algorithm eliminates the influence of installation error and image distortion to obtain the accurate actual coordinates of the welding target. The algorithm formula is as follows: ; in The actual three-dimensional coordinates of the welding target point; To locate the target point in the image acquired by the camera; The initial height of the target point calibrated for the camera; The focal length of the camera; This is the correction amount for equipment installation errors; The intelligent temperature control PID algorithm of the central control system (2) uses an incremental PID control algorithm to adjust the cooling airflow and water cooling circulation rate, so that the temperature of the welding area is stabilized within the preset threshold range and thermal deformation is suppressed. Its calculation formula is: ; ; in, This represents the increment of cooling airflow or cooling water flow corresponding to the k-th sample. This is the proportionality coefficient; The integral coefficient; These are the differential coefficients; The temperature deviation of the k-th sample; , To preset the temperature threshold, The actual welding temperature during the k-th sampling; This is the final control value for the k-th sample. This is the control quantity for the (k-1)th sample; The adaptive algorithm for welding parameters of the central control system (2) is based on the material of the power distribution switch assembly. ),thickness( ) and thermal conductivity ( Adaptive matching laser power ( ) and welding speed ( To ensure the weld penetration meets the standard and there is no excessive burn-off, the calculation formula is as follows: ; in This is a process correction factor, obtained by fitting historical qualified welding data from a parameter database, with a range of [range missing]. , ; For the density of the welding material, The thickness of the component weld joint. For the thermal conductivity of the material, For laser welding power, For welding speed Working principle: The welding process of the welding device used in the production and manufacturing of this power distribution switch assembly is as follows: Step 1: Parameter setting: The operator selects the specifications and model of the power distribution switch component to be welded through the touch screen of the central control system, and calls up the preset positioning parameters, clamping pressure parameters, welding parameters and temperature control parameters. Step 2: Loading the power distribution switch assembly. The operator places the power distribution switch assembly on the power distribution switch assembly pushing structure at the loading station. Step 3: Clean the dust on the workbench. Rotate the welding table to move the power distribution switch components to be welded to the bottom of the dust cleaning equipment. The dust cleaning equipment blows air to clean the welding area of ​​the components to remove impurities and dust. Step 4: Visual positioning; The rotating welding table continues to rotate to the positioning station. The positioning camera captures the positioning reference image of the component. The image processing module calculates the actual welding coordinates through the positioning coordinate correction algorithm. The central control system controls the adjustable positioning pin to fine-tune the positioning based on the calculation results. Then, it controls the pneumatic clamping component to move. The elastic pressure head clamps the component, and the pressure sensor provides real-time feedback of the clamping pressure to ensure that the pressure is within the preset range. Step 5: Welding of power distribution switch components. The central control system matches the laser power and welding speed through an adaptive welding parameter algorithm, controls the three-dimensional adjustable welding mechanism to move the laser welding head to the welding start position and start welding; at the same time, the intelligent temperature control and heat dissipation system adjusts the cooling airflow and cooling water flow through an incremental PID algorithm to control the temperature of the welding area to be stable at the preset threshold in real time. Step 6: Visual inspection. After welding is completed, the inspection camera captures images of the weld. The image processing module analyzes and judges the weld width, penetration depth, and surface defects, and feeds the inspection results back to the central control system. Step 7: Unloading. The workbench rotates to the unloading station. If the product is qualified, remind the worker to convey the qualified product to the conveyor line; if it is unqualified, the scrapped product needs to be transported to the product collection box.

[0019] The following points should be noted in this article: 1. The accompanying drawings of the embodiments disclosed herein only relate to the structures involved in the embodiments disclosed herein; other structures can be referred to in a general design.

[0020] 2. Where there is no conflict, the embodiments of this disclosure and the features in the embodiments can be combined with each other to obtain new embodiments.

[0021] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

Claims

1. A welding apparatus for manufacturing power distribution switch components, comprising a workbench, a rotary welding table, a power distribution switch component pushing structure, a three-dimensional adjustable welding mechanism, an intelligent temperature control and heat dissipation system, a visual positioning and detection system, and a central control system, characterized in that: The workbench is provided with a rotating welding table driven to rotate by a rotating motor, and a plurality of power distribution switch assembly pushing structures are uniformly arranged on the periphery of the rotating welding table, each of which is used to push the power distribution switch assembly to be processed to the rotating welding table for welding processing. The main body of the three-dimensional adjustable welding mechanism is a three-dimensional mechanical arm, which is rotatably arranged on the workbench, and a laser welding head and a visual positioning detection camera are arranged at the machining end of the three-dimensional mechanical arm, and a welding parameter adjusting module is integrated in the laser welding head, which can adjust the laser power, welding speed and spot size according to the welding material and thickness. The intelligent temperature control and heat dissipation system comprises an infrared temperature sensor, a cooling air jet assembly and a water cooling circulation assembly, the infrared temperature sensor is arranged beside the laser welding head, the cooling air jet assembly comprises an annular air jet nozzle coaxially sleeved outside the laser welding head, and the start-stop and flow of the cooling air are controlled by an electromagnetic valve, and the water cooling circulation assembly comprises a cooling water tank, a circulating water pump and a water cooling clamp, the water cooling clamp is embedded in the positioning base, and a circulation loop is formed between the water cooling clamp and the cooling water tank through a pipeline. The central control system is electrically connected with the rotating welding table, the power distribution switch assembly pushing structure, the three-dimensional adjustable welding mechanism, the intelligent temperature control and heat dissipation system and the visual positioning detection system, and the central control system is provided with a positioning coordinate correction algorithm, an incremental PID intelligent temperature control algorithm and a welding parameter adaptive algorithm, the positioning coordinate correction algorithm is used to convert the two-dimensional image coordinates collected by the visual positioning detection system into actual three-dimensional coordinates of the welding target point, the incremental PID intelligent temperature control algorithm is used to adjust the cooling air flow and the water cooling circulation rate to stabilize the welding area temperature, and the welding parameter adaptive algorithm is used to match the laser power and the welding speed according to the material, thickness and thermal conductivity of the power distribution switch assembly.

2. A power distribution switch assembly production welding apparatus as defined in claim 1, wherein: The top of the workbench is provided with a liftable mechanical arm, the output end of the liftable mechanical arm is provided with a dust cleaning device, the dust cleaning device is a high-power dust cleaning device, is located at the top of the rotating welding table and performs dust cleaning on the power distribution switch assembly before the welding process.

3. A power distribution switch assembly production welding apparatus as defined in claim 1, wherein: Each power distribution switch assembly pushing structure comprises a positioning base, an adjustable positioning pin, a pneumatic clamping assembly and a pressure sensor, the adjustable positioning pin fixes the power distribution switch through a locking bolt, the pneumatic clamping assembly is symmetrically arranged on both sides of the positioning base, and an elastic pressure head is arranged at the output end of the pneumatic clamping assembly and used to push the power distribution switch assembly to the rotating welding table, and the pressure sensor is integrated in the elastic pressure head.

4. The apparatus according to claim 1, wherein: One side of the workbench is provided with a qualified product conveying line and an unqualified product collecting box, and the central control system reminds the workers to classify and place the qualified products and the unqualified products according to the judgment result of the detection station.

5. The apparatus according to claim 1, wherein: The positioning coordinate correction algorithm of the central control system combines two-dimensional image information collected by a visual positioning detection camera with camera calibration parameters to complete three-dimensional coordinate conversion, eliminates the influence of installation errors and image distortion through a coordinate correction algorithm, and obtains accurate actual coordinates of the welding target point, and the algorithm formula is: ； wherein is the actual three-dimensional coordinate of the welding target point; acquiring pixel coordinates of the target point in the image captured by the positioning camera; initial height of the target point for camera calibration; focal length of the camera; Installs the error correction amount for the device.

6. A power distribution switch assembly production welding apparatus as defined in claim 1, wherein: The intelligent temperature control PID algorithm of the central control system adopts an incremental PID control algorithm to adjust the cooling airflow flow and the water cooling circulation rate, so that the welding area temperature is stably kept in a preset threshold range, and thermal deformation is inhibited, and the calculation formula is: ； ； wherein, is the corresponding cooling airflow flow rate increment or cooling water flow rate increment for the kth sample; is a proportional coefficient; is an integral coefficient; is a derivative coefficient; is the temperature deviation of the kth sample; , is a preset temperature threshold, is the actual welding temperature of the kth sampling the final control quantity for the kth sampling, the control quantity for the k-1th sampling.

7. A power distribution switch assembly production welding apparatus as defined in claim 1, wherein: The adaptive algorithm for welding parameters in the central control system is based on the material of the power distribution switch components ( ),thickness( ) and thermal conductivity ( Adaptive matching laser power ( ) and welding speed ( To ensure the weld penetration meets the standard and there is no excessive burn-off, the calculation formula is as follows: ； wherein is a process correction coefficient, fitted by the parameter database according to historical qualified welding data, with an interval range of , ; is the material density, is the component weld thickness, is the material thermal conductivity, is the laser welding power, is the welding speed.

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