Alternate synchronous welding equipment suitable for stainless steel

Abstract

The invention discloses alternate synchronous welding equipment suitable for stainless steel, and belongs to the technical field of welding equipment. Comprising a mounting base and a welding unit, an objective table, an angle module and a supporting inner frame are rapidly switched, typical components such as a multi-edge column, a spiral finned tube, a thin-wall corrugated tube and a micro-needle circular seam can be covered, the whole gun does not need to be replaced or a positioner does not need to be additionally arranged, and the remodeling downtime is short; by means of reciprocating swinging, transverse moving tracking and three-gun crossing, all-round alternate synchronous welding is achieved, multiple times of overturning and repositioning are avoided, and the production efficiency is remarkably improved; fixed-frequency excitation of the main beam is linked with stepped air cooling of the cooling ring, the inherent frequency is locked, the interlayer temperature is controllable, a thin wall is not burnt through, a thick edge is subjected to one-time penetration, distortion and oxidation color are avoided after welding, and clean assembly can be directly carried out; the five space postures of the angle module and the length of the supporting inner frame are decreased progressively, continuous positioning from a microneedle to a multi-edge column can be achieved, a welding gun is perpendicular to a local tangent line all the time, the fusion depth is uniform, and overhead welding and manual repair welding are omitted.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to an alternating synchronous welding device suitable for stainless steel. Background Technology

[0002] Stainless steel, due to its corrosion resistance, high-temperature strength, and bright appearance, is widely used in food, pharmaceuticals, petrochemicals, rail transportation, and building decoration. As products develop towards thinner walls, multi-ribbed surfaces, irregular shapes, and micro-diameters, traditional single-sided, single-pass, single-gun welding methods are no longer sufficient to meet the production requirements of high precision, high efficiency, and low deformation. Existing technological challenges include:

[0003] Multi-ribbed columns or irregularly shaped pipes require repeated manual or positioner rotation, resulting in numerous clamping operations, long cycle times, and large cumulative errors. Thin-walled corrugated pipes and micro-needle-like workpieces are heat-sensitive, and conventional continuous welding can easily burn through and create sensitized areas, requiring pickling and reshaping after welding. A single piece of equipment can usually only adapt to one type of waveform or number of edges. Changing the type requires replacing the entire set of fixtures and welding torches, resulting in long downtime. Manual or semi-automatic operation leads to poor weld formation, penetration depth, and color consistency, resulting in a large amount of subsequent grinding and rework. Therefore, an alternating synchronous welding equipment suitable for stainless steel is proposed. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and to propose an alternating synchronous welding device suitable for stainless steel.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: An alternating synchronous welding device for stainless steel includes a mounting base and a welding unit. The welding unit is mounted on the top of the mounting base. The mounting base includes a base and a main beam mounted in the middle of the base. A cooling ring is mounted on the top edge of the base. The welding unit includes a column and a swing module mounted between two sets of columns. A transverse module is mounted on the top of the column.

[0006] Preferably, the cooling ring includes an annular cavity and partitions installed around the inner wall of the annular cavity, a cooling group is installed between the four sets of partitions, a transition plate is installed on the upper end face of the partitions, and a nozzle is installed on the top of the transition plate. The main beam installed inside the base cavity vibrates at a fixed frequency, so that the natural frequency of the entire device is relatively positioned in the same frequency band.

[0007] The cooling system uses a bottom-in, top-out series airflow path—cooling gas enters from the first cooling unit at the bottom, passes through each vertically arranged cooling unit in stages, and finally is sprayed in layers from the transition plate to the nozzles onto the surface of the freshly welded component. This achieves the dual effect of "step-down cooling + clean purging," with the quantitative results as follows: Each cooling group has a flow rate of 8L / min. The total pressure drop after six groups are connected in series is 0.05MPa. The gas outlet temperature gradually increases from 20℃ to 45℃. The surface temperature drop rate of the component is 40℃ / s. The interlayer temperature is locked at ≤70℃.

[0008] The nozzle is a 30° flat nozzle with a slit width of 1mm, a spray speed of 20m / s, and a coverage width of 10mm, which just sweeps across the 8mm area at the tail of the molten pool, reducing the width of the oxide color to within 0.3mm.

[0009] Multiple cooling units are connected in series to form a stable laminar flow with a Reynolds number of Re≈1800, avoiding turbulent air entrainment. The oxygen content on the weld surface is ≤30ppm, meeting the requirements for food-grade gloss.

[0010] The upward emission of gas generates a reverse thrust of 0.6N, which is 180° out of phase with the 1290Hz excitation of the main beam, canceling out 10% of the mechanical amplitude, and the welding torch vibration decreases by 0.003mm.

[0011] Pure gas phase cooling eliminates droplet impact, allowing 0.3mm thin-walled corrugated pipes to proceed directly to the next assembly stage without drying after welding, thus shortening the cycle time by 6 seconds.

[0012] Preferably, the cooling assembly includes a distribution cavity and a rectifier plate installed inside the distribution cavity, wherein throttling rings are arranged laterally in the middle of the rectifier plate; The distribution chamber has a volume of 0.12L, an inner wall roughness of Ra0.8µm, and an airflow resistance coefficient of ≤0.15. It ensures that the pressure difference at the inlet of multiple throttling rings is <0.005MPa, the flow uniformity is ±2%, and the lateral temperature difference is ≤3℃ when multiple nozzles are opened simultaneously, thus avoiding local overheating that could cause the 0.3mm thin wall to burn through.

[0013] The rectifier plate has a honeycomb aperture of 2mm and an aspect ratio of 3:1. After rectification, the turbulence intensity decreases by 70%, the outlet airflow deflection angle is ≤1°, the angle between the spray centerline and the weld is always 30°±1°, and the width of the protective gas coverage at the tail of the molten pool is maintained at 10mm.

[0014] The opening of each throttling ring is adjustable from 0 to 1.2 mm, and the flow resolution of a single ring is 0.1 L / min; the flow rate is increased by 20% at the apex of the corrugation bend, the apex temperature drop rate is increased by 15℃ / s, and the overall interlayer temperature is locked at ≤70℃.

[0015] Preferably, the welding unit includes columns and a swing module installed between the columns, with a horizontally moving module installed at the top of the columns.

[0016] The swing module includes a housing and a drive shaft installed at the outer end of the housing. A rotary table is installed in the inner cavity of the housing. The drive shaft passes through the side wall of the housing and drives the rotary table to rotate axially. A platform is installed on the upper surface of the rotary table. The component to be processed is placed on the upper surface of the platform. The drive shaft passes through the side surface of the housing and drives the rotary table to reciprocate and rotate. When the rotary table reciprocates, the platform moves synchronously under its drive, reciprocating and rotating in the horizontal plane to dynamically position or adjust the angle of the component. This allows the welding head installed on the side surface of the transverse module to continuously weld different sides of the component in an alternating and synchronous manner.

[0017] All surfaces can be welded alternately and synchronously in a single clamping, eliminating the need for multiple flipping and repositioning, and greatly improving production efficiency.

[0018] The reciprocating oscillation and rotation are precisely synchronized with the welding head feed, ensuring that the weld bead formation, penetration depth and appearance of each weld bead are consistent, thus improving the overall quality of the weld.

[0019] The component swings back and forth on the platform along with the rotary table, and each edge automatically aligns with the welding head in sequence, eliminating the need for additional fixtures or positioners, thus reducing equipment costs and clamping errors.

[0020] During the oscillation process, the columnar ridgeline is always in the optimal position for the molten pool to bear force, which can effectively counteract thermal deformation, significantly reduce post-weld distortion and residual stress, and maintain the straightness of the column.

[0021] Preferably, the transverse module includes a base and guide rails mounted on both sides of the upper edge of the base. A slider is slidably mounted on the upper surface of the guide rails. A guide rod is transversely disposed in the middle of the slider. The two ends of the guide rod are respectively attached to the inner end surface of the base. An adapter plate is mounted on the upper surface of the slider, and a gun holder is mounted on the side end surface of the adapter plate. The welding head, mounted on one side of the gun holder, can reciprocate laterally with the upper end of the guide rail as the fulcrum, in cooperation with the slider and the guide rod, thereby adjusting its working position. When the stage drives the multi-faceted column to swing and change faces, the welding head can move laterally into the next faceted area in sync, so as to achieve consistent lateral movement of the column swinging welding gun and improve the overall welding efficiency. When the spiral finned tube needs to be processed, the stage drives the spiral finned tube to swing back and forth at a micro-angle. The welding head "tracks" the spiral angle of the fin along the guide rod laterally, realizing the segmented symmetrical welding of the ° continuous fillet weld and suppressing the thermal deformation of the fin.

[0022] The stage drives the spiral finned tube to swing back and forth at a micro angle of ±5°~±15°, so that the fillet weld at the root of the fin to be welded is always in the optimal molten pool flow position for flat welding or downslope welding, avoiding insufficient penetration caused by overhead welding.

[0023] The welding head moves laterally along the guide rod under the drive of the slider. Its displacement is matched with the pitch in real time. The helix angle parameter is fed back by the encoder to form a 1:1 synchronous relationship of "swing-lateral movement" to ensure that the wire extension is constant and the arc is always aligned with the fin-base tube joint surface. When processing the U-shaped bend section of the longitudinal seam of a thin-walled corrugated pipe, the curvature of the corrugated bend section changes greatly. This equipment uses small-angle reciprocating oscillation + fine transverse movement to ensure that the welding torch is always perpendicular to the tangential direction, ensuring uniform penetration and avoiding burn-through.

[0024] The gun body moves in real time with the curvature, the electric arc is always perpendicular to the wave surface, the molten pool is symmetrically stressed, the shape is consistent, the heat is applied symmetrically in segments, the corrugation rebound is small, no post-weld adjustment is required, overhead welding and manual repair welding are eliminated, and the entire longitudinal seam is completed in one go, which is suitable for thin-walled stainless steel corrugated pipes in clean working conditions.

[0025] Preferably, the welding unit further includes an angle module horizontally mounted on the upper surface of the rotary table. The angle module includes a base plate and a servo disk mounted on one side of the base plate, and a hollow shaft is mounted on the other end of the servo disk. When different structures need to be welded alternately and synchronously, the stage is removed and the angle module and the gun head module are horizontally installed on the upper surface of the rotary table. The side end of the base plate is fixedly installed on one side of the inner wall of the rotary table. During the installation of the angle module and the gun head module, the side end of the annular gun holder will not touch the upper surface of the rotary table. The hollow shaft is rotated by the servo disk. The spacing between the annular gun holder and multiple sets of standard nozzles can be used to weld and position small structures.

[0026] Furthermore, the three sets of ring gun holders in the ring array can cooperate at multiple angles. Every 120° rotation of the servo disk, the three sets of ring gun holders alternately give way, forming a multi-angle intersection entrance. The previous gap is exited and the next gap is immediately filled, realizing continuous switching of "positioning and welding at the same time". Small structures can be clamped once to complete multi-face alternating synchronous welding. Through the adjustment of the multi-joint structure between the hollow shaft, hinge, and ring gun base, the gun head module as a whole can be adjusted at multiple angles, thereby positioning different structures.

[0027] The hollow shaft rotation axis returns to zero, so that the three sets of gun head modules are in the same plane, with the gun tips pointing to 0°, forming a horizontal array in the shape of "I". This is suitable for 0° flat welding. In this posture, the three guns are in the same plane and the gun tips are in the same direction, which is suitable for butt welding of flat thin plates and longitudinal seam welding.

[0028] The hinge swings up and down by ±30°, then the two outer gun head modules rise, while the middle one remains horizontal, forming a "duck wing" layout. This allows for simultaneous downslope welding of the fillet welds on both sides of the "∧" shaped bevel. In this configuration, the two outer guns rise 30°, and the middle gun remains horizontal. This configuration is suitable for small-sized T-joints and micro-support reinforcements.

[0029] The hollow shaft rotates 60° as a whole, and the hinges each swing 15° in the opposite direction. The tips of the three guns have a stepped difference in the Z direction, forming a 30° spiral line, which matches the spiral angle of the spiral finned tube, realizing 360° segmented symmetrical welding. In this posture, the three guns are misaligned in the Z direction to form a 30° spiral line. It is suitable for fillet welds of spiral finned tubes and spiral coils, and completes 360° segmented symmetrical welding in one go.

[0030] The hollow shaft continues to rotate 120°, and the three sets of gun head modules are staggered by 40° in sequence. The gun bodies intersect in space to form a "star" shape, without interfering with each other. This allows for alternating synchronous welding of any two adjacent ridges of a hexagonal column, eliminating the need for a positioner. In this posture, the three gun planes are 120° apart and spatially staggered. This is suitable for alternating welding of small multi-ridge sensor housings and honeycomb column sections on adjacent ridges of hexagonal and octagonal columns.

[0031] Synchronous inward contraction, the three guns swing concentrically to within a 5mm radius circumference with the gun tips almost touching, but each deflected by 15°, forming a "conical cluster". This allows for circumferential positioning welding of φ0.2mm microneedles, with the intersection points concentrated at one point, resulting in symmetrical heat release and preventing burn-through. This configuration, with the three guns converging concentrically and the cone apex concentrated, is suitable for circumferential positioning welding of microneedles, microshafts, capillary tubes, medical injection needles, and fiber optic protective sleeves.

[0032] Preferably, the welding unit further includes a gun head module axially mounted on the outer ring of the hollow shaft. The gun head module includes an annular gun seat and a fixing surface mounted on the side end face of the annular gun seat. A standard nozzle is laterally opened in the inner cavity of the annular gun seat. The gun head module also includes a support inner frame that can replace the standard nozzle. The lengths of multiple sets of support inner frames are successively shortened downwards. An alternative embodiment is proposed, in which the standard nozzle is replaced with a support inner frame. The support inner frame is a set of quick-change nozzle inner frames with decreasing length and different outlet angles. The nozzle extension and spray angle can be changed by plugging and unplugging. The nozzle can be switched between flat top, narrow bevel and deep groove without disassembling the whole gun.

[0033] The long nozzle extends into the deep groove or fin root, while the short nozzle remains at the shallow bevel or flat surface, achieving flexible welding with "multiple penetration depths on the same frame".

[0034] Each of the three guns can independently replace the inner support frame, and the "long-short-medium" combination can be completed on site within 5 seconds. The plate, vertical plate and micro-ribs can be welded at the same time, saving the need to stop the machine when changing guns.

[0035] The outlet shape changes from a straight hole to a flat or expanded opening, which can concentrate or disperse the arc heat and adjust the coverage of the protective gas. Thin-walled parts are not easy to burn through, while thick-edged parts can still be melted through.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The platform, angle module, and inner support frame can be quickly switched to cover typical components such as multi-ridged columns, spiral finned tubes, thin-walled corrugated tubes, and micro-needle circumferential seams, without the need to replace the entire gun or add an external positioner, resulting in short downtime for model changeovers.

[0037] 2. Reciprocating oscillation plus transverse tracking plus three-gun cross welding achieves full-circumference alternating synchronous welding, eliminating multiple flipping and repositioning, significantly improving production efficiency; the main beam's fixed frequency excitation and cooling ring's stepped air cooling linkage lock the natural frequency, controllable interlayer temperature, thin walls do not burn through, thick edges are melted through in one go, and there is no twisting or oxidation color after welding, allowing it to directly enter clean assembly.

[0038] 3. The angle module has five spatial postures with decreasing support inner frame length, which can continuously position micro needles to multi-ridged columns. The welding gun is always perpendicular to the local tangent, resulting in uniform penetration depth. It eliminates overhead welding and manual re-welding. The support inner frame can be plugged in and replaced, and the nozzle length and angle can be switched in a short time. Wear only occurs in the low-cost inner frame. The main gun holder does not move for a long time, which greatly reduces spare parts costs and maintenance time. Attached Figure Description

[0039] Figure 1 This is a three-dimensional structural diagram of an alternating synchronous welding device for stainless steel proposed in this invention. Figure 2 This is a schematic diagram of the mounting base structure of an alternating synchronous welding device for stainless steel proposed in this invention. Figure 3 This is a schematic diagram of a cooling ring structure for an alternating synchronous welding device for stainless steel, as proposed in this invention. Figure 4 This is a schematic diagram of the cooling group structure of an alternating synchronous welding device for stainless steel proposed in this invention; Figure 5 This is a schematic diagram of the oscillating module structure of an alternating synchronous welding device for stainless steel proposed in this invention; Figure 6 This is a schematic diagram of the transverse movement module structure of an alternating synchronous welding device for stainless steel proposed in this invention; Figure 7 This is a schematic diagram of the angle module and gun head module structure of an alternating synchronous welding equipment for stainless steel proposed in this invention; Figure 8 This is a bottom view of the angle module and gun head module of an alternating synchronous welding device for stainless steel proposed in this invention; Figure 9 This is a schematic diagram of the supporting inner frame structure of an alternating synchronous welding equipment for stainless steel proposed in this invention.

[0040] In the diagram: 1. Mounting base; 11. Base; 12. Main beam; 13. Cooling ring; 131. Annular cavity; 132. Partition plate; 133. Cooling assembly; 1331. Distribution cavity; 1332. Rectifier plate; 1333. Throttling ring; 134. Transition plate; 135. Nozzle; 2. Welding unit; 21. Column; 22. Swing module; 221. Housing; 222. Drive shaft; 223. Rotary table; 224. Platform; 23. Lateral module; 231. Base; 232. Guide rail; 233. Slider; 234. Guide rod; 235. Adapter plate; 236. Gun holder; 24. Angle module; 241. Base plate; 242. Servo disk; 243. Hollow shaft; 25. Gun head module; 251. Annular gun holder; 252. Fixing surface; 253. Standard nozzle; 254. Support inner frame. Detailed Implementation

[0041] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0042] Reference Figures 1-9 Example 1: An alternating synchronous welding device suitable for stainless steel includes a mounting base 1 and a welding unit 2. The welding unit 2 is mounted on the top of the mounting base 1. The mounting base 1 includes a base 11 and a main beam 12 mounted in the middle of the base 11. A cooling ring 13 is mounted on the top edge of the base 11. The welding unit 2 includes a column 21 and a swing module 22 mounted between two sets of columns 21. A transverse module 23 is mounted on the top of the column 21.

[0043] The cooling ring 13 includes an annular cavity 131 and partitions 132 installed around the inner wall of the annular cavity 131. Cooling groups 133 are installed between the four partitions 132. Transition plates 134 are installed on the upper end face of the partitions 132. Nozzles 135 are installed on the top of the transition plates 134. The main beam 12, installed inside the base 11, vibrates at a fixed frequency, so that the natural frequency of the entire device is relatively positioned in the same frequency band.

[0044] The cooling unit 133 uses a "bottom-in, top-out" series airflow path—cooling gas enters from the bottom first cooling unit 133, passes through each vertically arranged cooling unit 133 in stages, and finally is sprayed in layers onto the surface of the freshly welded component through the transition plate 134 and nozzle 135, achieving the dual effect of "step-down cooling + clean purging". The quantitative effect is as follows: Each cooling group has a flow rate of 8L / min and six groups connected in series. The total pressure drop is 0.05MPa. The gas outlet temperature gradually increases from 20℃ to 45℃. The surface temperature drop rate of the component is 40℃ / s, and the interlayer temperature is locked at ≤70℃.

[0045] Nozzle 135 is a 30° flat nozzle with a slit width of 1mm, a spray speed of 20m / s, and a coverage width of 10mm. It sweeps across the 8mm area at the tail of the molten pool, reducing the width of the oxide color to within 0.3mm.

[0046] Multiple cooling units (133) are connected in series to form a stable laminar flow with a Reynolds number (Re≈1800), avoiding turbulent air entrainment. The oxygen content on the weld surface is ≤30ppm, meeting the requirements for food-grade gloss.

[0047] The upward emission of gas generates a reverse thrust of 0.6N, which is 180° out of phase with the 1290Hz excitation of the main beam, canceling out 10% of the mechanical amplitude, and the welding torch vibration decreases by 0.003mm.

[0048] Pure gas phase cooling eliminates droplet impact, allowing 0.3mm thin-walled corrugated pipes to proceed directly to the next assembly stage without drying after welding, thus shortening the cycle time by 6 seconds.

[0049] Example 2: The cooling assembly 133 includes a distribution cavity 1331 and a rectifier plate 1332 installed in the inner cavity of the distribution cavity 1331. Throttling rings 1333 are arranged laterally in the middle of the rectifier plate 1332. The distribution chamber 1331 has a volume of 0.12L, an inner wall roughness of Ra0.8µm, and an airflow resistance coefficient of ≤0.15. It ensures that the inlet pressure difference of multiple throttling rings 1333 is <0.005MPa, the flow uniformity is ±2%, and the lateral temperature difference is ≤3℃ when multiple nozzles are opened at the same time, avoiding local overheating that could cause the 0.3mm thin wall to burn through.

[0050] The rectifier plate has a 1332 honeycomb aperture of 2mm and an aspect ratio of 3:1. After rectification, the turbulence intensity decreases by 70%, the outlet airflow deflection angle is ≤1°, the angle between the spray centerline and the weld is always 30°±1°, and the width of the protective gas coverage at the tail of the molten pool is maintained at 10mm.

[0051] The throttling ring 1333 has an adjustable opening of 0–1.2 mm per ring, and a single ring flow resolution of 0.1 L / min; the flow rate is increased by 20% at the apex of the corrugated bend, the apex temperature drop rate is increased by 15℃ / s, and the overall interlayer temperature is locked at ≤70℃.

[0052] In Example 3, the welding unit 2 includes a column 21 and a swing module 22 installed between the columns 21. A transverse module 23 is installed horizontally at the top of the column 21.

[0053] The swing module 22 includes a housing 221 and a drive shaft 222 installed at the outer end of the housing 221. A rotary table 223 is installed in the inner cavity of the housing 221. The drive shaft 222 passes through the side wall of the housing 221 and drives the rotary table 223 to rotate axially. A platform 224 is installed on the upper end face of the rotary table 223. The component to be processed is placed on the upper surface of the stage 224. The drive shaft 222 passes through the side surface of the housing 221 and drives the rotary table 223 to reciprocate and rotate. When the rotary table 223 reciprocates, the stage 224 moves synchronously under its drive and reciprocates and rotates in the horizontal plane to dynamically position or adjust the angle of the component. This allows the welding head installed on the side surface of the transverse module 23 to continuously weld different sides of the component in an alternating and synchronous manner.

[0054] All surfaces can be welded alternately and synchronously in a single clamping, eliminating the need for multiple flipping and repositioning, and greatly improving production efficiency.

[0055] The reciprocating oscillation and rotation are precisely synchronized with the welding head feed, ensuring that the weld bead formation, penetration depth and appearance of each weld bead are consistent, thus improving the overall quality of the weld.

[0056] The component reciprocates along a fixed axis on the stage 224 with the rotary table 223, and each edge automatically aligns with the welding head in sequence, eliminating the need for additional fixtures or positioners, thus reducing equipment costs and clamping errors.

[0057] During the oscillation process, the columnar ridgeline is always in the optimal position for the molten pool to bear force, which can effectively counteract thermal deformation, significantly reduce post-weld distortion and residual stress, and maintain the straightness of the column.

[0058] Example 4: The transverse module 23 includes a base 231 and guide rails 232 installed on both sides of the upper edge of the base 231. A slider 233 is slidably installed on the upper surface of the guide rails 232. A guide rod 234 is transversely arranged through the middle of the slider 233. The two ends of the guide rod 234 are respectively attached to the inner end surface of the base 231. An adapter plate 235 is installed on the upper surface of the slider 233. A gun holder 236 is installed on the side end surface of the adapter plate 235. The welding head installed on one side of the gun holder 236 can reciprocate laterally with the upper end face of the guide rail 232 as the fulcrum under the cooperation of the slider 233 and the guide rod 234, thereby adjusting its working position. When the stage 224 drives the multi-faceted column to swing and change its surface, the welding head can move laterally into the next faceted area in sync, so as to realize the consistent lateral movement rhythm of the column swing welding gun and improve the overall welding efficiency. In Example 5, when the spiral finned tube needs to be processed, the stage 224 drives the spiral finned tube to swing back and forth at a micro-angle, and the welding head "tracks" the spiral angle of the fin laterally along the guide rod 234 to achieve segmented symmetrical welding of 360° continuous fillet welds and suppress fin thermal deformation.

[0059] The stage 224 drives the spiral finned tube to reciprocate at a micro-angle of ±5°~±15°, so that the fillet weld at the root of the fin to be welded is always in the optimal molten pool flow position for flat welding or downslope welding, avoiding insufficient penetration caused by overhead welding.

[0060] Driven by slider 233, the welding head moves laterally along guide rod 234. Its displacement is matched with the pitch in real time. The encoder feeds back the helix angle parameter to form a 1:1 synchronous relationship of "swing-lateral movement" to ensure that the wire extension is constant and the arc is always aligned with the fin-base tube joint surface. When processing the U-shaped bend section of the longitudinal seam of a thin-walled corrugated pipe, the curvature of the corrugated bend section changes greatly. This equipment uses small-angle reciprocating oscillation + fine transverse movement to ensure that the welding torch is always perpendicular to the tangential direction, ensuring uniform penetration and avoiding burn-through.

[0061] The gun body moves in real time with the curvature, the electric arc is always perpendicular to the wave surface, the molten pool is symmetrically stressed, the shape is consistent, the heat is applied symmetrically in segments, the corrugation rebound is small, no post-weld adjustment is required, overhead welding and manual repair welding are eliminated, and the entire longitudinal seam is completed in one go, which is suitable for thin-walled stainless steel corrugated pipes in clean working conditions.

[0062] In Example 6, the welding unit 2 further includes an angle module 24 that is horizontally mounted on the upper surface of the rotary table 223. The angle module 24 includes a base plate 241 and a servo disk 242 mounted on one side of the base plate 241. A hollow shaft 243 is mounted on the other end of the servo disk 242. When different structures need to be welded alternately and synchronously, the stage 224 is removed and the angle module 24 and the gun head module 25 are horizontally installed on the upper surface of the rotary table 223. The side surface of the base plate 241 is fixedly installed on one side of the inner wall of the rotary table 223. During the installation of the angle module 24 and the gun head module 25, the side surface of the annular gun holder 251 will not touch the upper surface of the rotary table 223. The hollow shaft 243 is rotated by the servo disk 242. The annular gun holder 251 and the interval between the multiple sets of standard nozzles 253 can be used to weld and position small structures.

[0063] Furthermore, the three sets of ring gun holders 251 in the ring array can cooperate with each other at multiple angles. Every time the servo disk 242 rotates 120°, the three sets of ring gun holders 251 alternately give way to form a multi-angle cross entrance. The previous gap exits and the next gap immediately fills in, realizing continuous switching of "positioning and welding at the same time". Small structures can be clamped once to complete multi-face alternating synchronous welding. Through the multi-joint structure adjustment between the hollow shaft 243, hinge 244 and annular gun base 251, the gun head module 25 can be adjusted at multiple angles to position different structures.

[0064] In Example 7, the hollow shaft 243 rotates to zero so that the three sets of gun head modules 25 are on the same plane, with the gun tips pointing to 0°, forming a horizontal array in the shape of "I". This is suitable for 0° flat welding. In this posture, the three guns are on the same plane and the gun tips are in the same direction, which is suitable for butt welding of flat thin plates and longitudinal seam welding.

[0065] Example 8: The hinge 244 swings up and down by ±30°, then the two outer sets of gun head modules 25 rise, while the middle set remains horizontal, forming a "duck wing" layout. This allows for simultaneous downslope welding of the fillet welds on both sides of the "∧" shaped bevel. In this configuration, the two outer guns rise 30°, and the middle gun remains horizontal. This configuration is suitable for small-sized T-shaped joints and micro-support reinforcing ribs.

[0066] In Example 9, the hollow shaft 243 rotates 60° as a whole, and the hinges 244 each swing 15° in the opposite direction. The tips of the three guns have a stepped difference in the Z direction, forming a 30° spiral line, which matches the spiral angle of the spiral finned tube, to achieve 360° segmented symmetrical welding. In this posture, the three guns are misaligned in the Z direction to form a 30° spiral line. This is suitable for fillet welds of spiral finned tubes and spiral coils, and completes 360° segmented symmetrical welding in one go.

[0067] In Example 10, the hollow shaft 243 continues to rotate 120°, and the three sets of gun head modules 25 are staggered by 40° in sequence → the gun bodies intersect in space to form a "star" shape, without interfering with each other, and can alternately and synchronously weld any two adjacent ridges of the hexagonal column, eliminating the need for a positioner. In this posture, the three gun planes are 120° apart and spatially staggered; it is suitable for alternating welding of small multi-ridge sensor shells and honeycomb column sections on adjacent ridges of hexagonal and octagonal columns.

[0068] Example 11: Synchronous inward retraction, with three guns swinging concentrically to within a 5mm radius circumference and the gun tips almost touching, but each deflected by 15°, forming a "conical cluster". This allows for circumferential positioning welding of φ0.2mm microneedles, with the intersection points concentrated at one point, resulting in symmetrical heat release and preventing burn-through. This configuration, with the three guns converging concentrically and the cone apex concentrated, is suitable for circumferential positioning welding of microneedles, microshafts, capillary tubes, medical injection needles, and fiber optic protective sleeves.

[0069] In embodiment 12, the welding unit 2 further includes a gun head module 25 axially mounted on the outer ring of the hollow shaft 243. The gun head module 25 includes an annular gun seat 251 and a fixing surface 252 mounted on the side end face of the annular gun seat 251. A standard nozzle 253 is laterally opened in the inner cavity of the annular gun seat 251. The gun head module 25 also includes a support inner frame 254 that can replace the standard nozzle 253. The lengths of multiple sets of support inner frames 254 are successively shortened downwards. An alternative embodiment is proposed, in which the standard nozzle 253 is replaced with a support inner frame 254. The support inner frame 254 is a set of quick-change nozzle inner frames with decreasing length and different outlet angles. The nozzle extension and spray angle can be changed by plugging and unplugging. The nozzle can be switched between flat top, narrow bevel and deep groove without disassembling the whole gun.

[0070] The long nozzle extends into the deep groove or fin root, while the short nozzle remains at the shallow bevel or flat surface, achieving flexible welding with "multiple penetration depths on the same frame".

[0071] Each of the three guns can independently replace the 254 inner support frame, and the "long-short-medium" combination can be completed on site within 5 seconds. The plate, vertical plate and micro-ribs can be welded at the same time, saving the need to stop the machine when changing guns.

[0072] The outlet shape changes from a straight hole to a flat or expanded opening, which can concentrate or disperse the arc heat and adjust the coverage of the protective gas. Thin-walled parts are not easy to burn through, while thick-edged parts can still be melted through.

[0073] In summary: The component to be processed is placed on the upper surface of the stage 224. The drive shaft 222 passes through the side surface of the housing 221, driving the rotary table 223 to reciprocate and rotate. When the rotary table 223 reciprocates, the stage 224 moves synchronously under its drive, reciprocating and rotating in the horizontal plane to dynamically position or adjust the angle of the component. This allows the welding head installed on the side surface of the transverse module 23 to continuously weld different sides of the component in an alternating and synchronous manner.

[0074] All surfaces can be welded alternately and synchronously in a single clamping, eliminating the need for multiple flipping and repositioning, and greatly improving production efficiency.

[0075] The reciprocating oscillation and rotation are precisely synchronized with the welding head feed, ensuring that the weld bead formation, penetration depth and appearance of each weld bead are consistent, thus improving the overall quality of the weld.

[0076] The component reciprocates along a fixed axis on the stage 224 with the rotary table 223, and each edge automatically aligns with the welding head in sequence, eliminating the need for additional fixtures or positioners, thus reducing equipment costs and clamping errors.

[0077] During the oscillation process, the columnar ridgeline is always in the optimal position for the molten pool to bear force, which can effectively counteract thermal deformation, significantly reduce post-weld distortion and residual stress, and maintain the straightness of the column.

[0078] The welding head installed on one side of the gun holder 236 can reciprocate laterally with the upper end face of the guide rail 232 as the fulcrum, in cooperation with the slider 233 and the guide rod 234, thereby adjusting its working position. When the stage 224 drives the multi-faceted column to swing and change its surface, the welding head can move laterally into the next faceted area in sync, so as to realize the consistent lateral movement rhythm of the column swinging welding gun and improve the overall welding efficiency.

[0079] When the spiral finned tube needs to be processed, the stage 224 drives the spiral finned tube to swing back and forth at a micro-angle. The welding head "tracks" the spiral angle of the fin laterally along the guide rod 234 to achieve segmented symmetrical welding of 360° continuous fillet welds and suppress thermal deformation of the fins.

[0080] The stage 224 drives the spiral finned tube to reciprocate at a micro-angle of ±5°~±15°, so that the fillet weld at the root of the fin to be welded is always in the optimal molten pool flow position for flat welding or downslope welding, avoiding insufficient penetration caused by overhead welding.

[0081] Driven by slider 233, the welding head moves laterally along guide rod 234. Its displacement is matched with the pitch in real time. The encoder feeds back the helix angle parameter to form a 1:1 synchronous relationship of "swing-lateral movement", which ensures that the wire extension is constant and the arc is always aligned with the fin-base tube joint surface.

[0082] When processing the U-shaped bend section of the longitudinal seam of a thin-walled corrugated pipe, the curvature of the corrugated bend section changes greatly. This equipment uses small-angle reciprocating oscillation + fine transverse movement to ensure that the welding torch is always perpendicular to the tangential direction, ensuring uniform penetration and avoiding burn-through.

[0083] The gun body moves in real time with the curvature, the electric arc is always perpendicular to the wave surface, the molten pool is symmetrically stressed, the shape is consistent, the heat is applied symmetrically in segments, the corrugation rebound is small, no post-weld adjustment is required, overhead welding and manual repair welding are eliminated, and the entire longitudinal seam is completed in one go, which is suitable for thin-walled stainless steel corrugated pipes in clean working conditions.

[0084] The main beam 12, installed inside the base 11, vibrates at a fixed frequency, so that the natural frequency of the entire device is relatively positioned in the same frequency band.

[0085] The cooling unit 133 uses a "bottom-in, top-out" series airflow path—cooling gas enters from the bottom first cooling unit 133, passes through each vertically arranged cooling unit 133 in stages, and finally is sprayed in layers onto the surface of the freshly welded component through the transition plate 134 and nozzle 135, achieving the dual effect of "step-down cooling + clean purging". The quantitative effect is as follows: Each cooling group has a flow rate of 8L / min and six groups connected in series. The total pressure drop is 0.05MPa. The gas outlet temperature gradually increases from 20℃ to 45℃. The surface temperature drop rate of the component is 40℃ / s, and the interlayer temperature is locked at ≤70℃.

[0086] Nozzle 135 is a 30° flat nozzle with a slit width of 1mm, a spray speed of 20m / s, and a coverage width of 10mm. It sweeps across the 8mm area at the tail of the molten pool, reducing the width of the oxide color to within 0.3mm.

[0087] Multiple cooling units (133) are connected in series to form a stable laminar flow with a Reynolds number (Re≈1800), avoiding turbulent air entrainment. The oxygen content on the weld surface is ≤30ppm, meeting the requirements for food-grade gloss.

[0088] The upward emission of gas generates a reverse thrust of 0.6N, which is 180° out of phase with the 1290Hz excitation of the main beam, canceling out 10% of the mechanical amplitude, and the welding torch vibration decreases by 0.003mm.

[0089] Pure gas phase cooling eliminates droplet impact, allowing 0.3mm thin-walled corrugated pipes to proceed directly to the next assembly stage without drying after welding, thus shortening the cycle time by 6 seconds.

[0090] The distribution chamber 1331 has a volume of 0.12L, an inner wall roughness of Ra0.8µm, and an airflow resistance coefficient of ≤0.15. It ensures that the inlet pressure difference of multiple throttling rings 1333 is <0.005MPa, the flow uniformity is ±2%, and the lateral temperature difference is ≤3℃ when multiple nozzles are opened at the same time, avoiding local overheating that could cause the 0.3mm thin wall to burn through.

[0091] The rectifier plate has a 1332 honeycomb aperture of 2mm and an aspect ratio of 3:1. After rectification, the turbulence intensity decreases by 70%, the outlet airflow deflection angle is ≤1°, the angle between the spray centerline and the weld is always 30°±1°, and the width of the protective gas coverage at the tail of the molten pool is maintained at 10mm.

[0092] The throttling ring 1333 has an adjustable opening of 0–1.2 mm per ring, and a single ring flow resolution of 0.1 L / min; the flow rate is increased by 20% at the apex of the corrugated bend, the apex temperature drop rate is increased by 15℃ / s, and the overall interlayer temperature is locked at ≤70℃.

[0093] When different structures need to be welded alternately and synchronously, the stage 224 is removed and the angle module 24 and the gun head module 25 are horizontally installed on the upper surface of the rotary table 223. The side surface of the base plate 241 is fixedly installed on one side of the inner wall of the rotary table 223. During the installation of the angle module 24 and the gun head module 25, the side surface of the annular gun holder 251 will not touch the upper surface of the rotary table 223. The hollow shaft 243 is rotated by the servo disk 242. The annular gun holder 251 and the interval between the multiple sets of standard nozzles 253 can be used to weld and position small structures.

[0094] Furthermore, the three sets of annular gun holders 251 in the annular array can cooperate at multiple angles. Every time the servo disk 242 rotates 120°, the three sets of annular gun holders 251 alternately move aside to form a multi-angle intersection entrance. The previous gap exits and the next gap immediately fills in, realizing continuous switching of "positioning and welding at the same time". Small structures can be clamped once to complete multi-face alternating synchronous welding.

[0095] Through the multi-joint structure adjustment between the hollow shaft 243, hinge 244 and annular gun base 251, the gun head module 25 can be adjusted at multiple angles to position different structures.

[0096] The hollow shaft 243 rotates to zero, so that the three sets of gun head modules 25 are on the same plane, with the gun tips pointing to 0°, forming a horizontal array in a "I" shape, which is suitable for 0° flat welding. In this posture, the three guns are on the same plane and the gun tips are in the same direction, which is suitable for butt welding of flat thin plates and longitudinal seam welding.

[0097] Hinges 244 swing up and down ±30°, then the two outer gun head modules 25 rise, while the middle one remains horizontal, forming a "duck wing" layout. This allows for simultaneous downslope welding of fillet welds on both sides of the "∧" shaped bevel. In this configuration, the two outer guns rise 30°, while the middle gun remains horizontal. This configuration is suitable for small-sized T-joints and micro-support reinforcements.

[0098] The hollow shaft 243 rotates 60° as a whole, and the hinges 244 each swing 15° in the opposite direction. The tips of the three guns have a stepped difference in the Z direction, forming a 30° spiral line, which matches the spiral angle of the spiral finned tube, realizing 360° segmented symmetrical welding. In this posture, the three guns are misaligned in the Z direction to form a 30° spiral line. It is suitable for fillet welds of spiral finned tubes and spiral coils, and completes 360° segmented symmetrical welding in one go.

[0099] The hollow shaft 243 continues to rotate 120°, and the three sets of gun head modules 25 are staggered by 40° in sequence. The gun bodies intersect in space to form a "star" shape, without interfering with each other. This allows for alternating synchronous welding of any two adjacent surfaces of a hexagonal column, eliminating the need for a positioner. In this posture, the three gun planes are 120° apart and spatially staggered. This is suitable for alternating welding of small multi-faceted sensor housings and honeycomb column sections on adjacent surfaces of hexagonal and octagonal columns.

[0100] Synchronous inward contraction, the three guns swing concentrically to within a 5mm radius circumference with the gun tips almost touching, but each deflected by 15°, forming a "conical cluster". This allows for circumferential positioning welding of φ0.2mm microneedles, with the intersection points concentrated at one point, resulting in symmetrical heat release and preventing burn-through. This configuration, with the three guns converging concentrically and the cone apex concentrated, is suitable for circumferential positioning welding of microneedles, microshafts, capillary tubes, medical injection needles, and fiber optic protective sleeves.

[0101] An alternative embodiment is proposed, in which the standard nozzle 253 is replaced with a support inner frame 254. The support inner frame 254 is a set of quick-change nozzle inner frames with decreasing length and different outlet angles. The nozzle extension and spray angle can be changed by plugging and unplugging. The nozzle can be switched between flat top, narrow bevel and deep groove without disassembling the whole gun.

[0102] The long nozzle extends into the deep groove or fin root, while the short nozzle remains at the shallow bevel or flat surface, achieving flexible welding with "multiple penetration depths on the same frame".

[0103] Each of the three guns can independently replace the 254 inner support frame, and the "long-short-medium" combination can be completed on site within 5 seconds. The plate, vertical plate and micro-ribs can be welded at the same time, saving the need to stop the machine when changing guns.

[0104] The outlet shape changes from a straight hole to a flat or expanded opening, which can concentrate or disperse the arc heat and adjust the coverage of the protective gas. Thin-walled parts are not easy to burn through, while thick-edged parts can still be melted through.

[0105] The above describes the entire working principle of this invention.

[0106] In this invention, the installation, connection or setting methods of all the components mentioned above are common mechanical methods, and the specific structure, model and coefficient index of all the components are their own technologies. As long as they can achieve their beneficial effects, they can be implemented, so they will not be described in detail.

[0107] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

[0108] In this invention, unless otherwise stated, directional terms such as "up, down, left, right, front, back, inside, outside, and vertical and horizontal" in the terminology only represent the orientation of the term in its conventional use or are common terms understood by those skilled in the art, and should not be regarded as limitations on the term. At the same time, numerals such as "first," "second," and "third" do not represent specific quantities or orders, but are merely used to distinguish names. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

Claims

1. An apparatus for alternate synchronous welding of stainless steel, comprising a mounting base (1) and a welding unit (2), characterized in that, The mounting base (1) is provided with a welding unit (2) mounted on the top thereof, the mounting base (1) comprises a base (11) and a main beam (12) mounted on the middle of the base (11), a cooling ring (13) is mounted on the top edge of the base (11), the welding unit (2) comprises a column (21) and a swing module (22) mounted between two groups of columns (21), a horizontal moving module (23) is mounted on the top of the column (21).

2. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 1 wherein, The cooling ring (13) comprises a ring cavity (131) and a partition plate (132) mounted on the wall of the inner cavity of the ring cavity (131), a cooling group (133) is mounted between four groups of partition plates (132), a transition plate (134) is mounted on the upper end face of the partition plate (132), and a nozzle (135) is mounted on the top of the transition plate (134).

3. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 2 wherein, The cooling group (133) comprises a distribution cavity (1331) and a flow regulating plate (1332) mounted in the inner cavity of the distribution cavity (1331), and a throttle ring (1333) is mounted on the middle of the flow regulating plate (1332) in a transverse arrangement.

4. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 1 wherein, The welding unit (2) comprises a column (21) and a swing module (22) mounted between the columns (21), and a horizontal moving module (23) is transversely mounted on the uppermost position of the column (21).

5. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 4 wherein, The swing module (22) comprises a housing (221) and a drive shaft (222) mounted on the outer end position of the housing (221), a rotary table (223) is mounted in the inner cavity of the housing (221), the drive shaft (222) penetrates through the side end wall of the housing (221) to drive the rotary table (223) to rotate axially, and a worktable (224) is mounted on the upper end face of the rotary table (223).

6. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 4 wherein, The horizontal moving module (23) comprises a base (231) and guide rails (232) mounted on the upper end face edges of the base (231), a sliding block (233) is slidingly mounted on the upper end face of the guide rail (232), a guide rod (234) is transversely arranged in the middle of the sliding block (233), the two ends of the guide rod (234) are respectively attached to the inner end faces of the base (231), a conversion plate (235) is mounted on the upper end face of the sliding block (233), and a gun seat (236) is mounted on the side end face of the conversion plate (235).

7. The apparatus for alternate synchronized welding of stainless steel as claimed in claim 5 wherein, The welding unit (2) further comprises an angle module (24) transversely mounted on the upper end face of the rotary table (223), the angle module (24) comprises a base plate (241) and a servo disc (242) mounted on one side of the base plate (241), and a hollow shaft (243) is mounted on the other end of the servo disc (242).

8. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 7 wherein, The welding unit (2) further comprises a gun head module (25) axially mounted on the outer ring of the hollow shaft (243), the gun head module (25) comprises an annular gun seat (251) and a fixing surface (252) mounted on the side end face of the annular gun seat (251), and a standard nozzle (253) is transversely arranged in the inner cavity of the annular gun seat (251).

9. The apparatus for alternate synchronous welding of stainless steel as claimed in claim 8 wherein, The gun head module (25) further comprises a support inner frame (254) capable of replacing the standard nozzle (253), and a plurality of support inner frames (254) are sequentially shortened in length from top to bottom.

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