Automatic welding equipment and method

Abstract

The invention relates to the technical field of welding automation, in particular to automatic welding equipment and method.The automatic welding equipment comprises a base, a walking mechanism, a visual recognition module, a welding execution unit, a welding unit and a control unit, the walking mechanism adopts Mecanum wheels with the wheel faces made of flexible magnetic attraction materials, so that the walking mechanism has the omni-directional moving capacity and the high adhesion capacity; the visual recognition module is used for weld joint positioning and real-time molten pool monitoring, the welding execution unit comprises a multi-degree-of-freedom mechanical arm and a clamping assembly and can achieve all-position posture adjustment of a welding gun, the welding unit can be configured to be shielded metal arc welding or flux-cored gas arc welding, and the control unit controls the welding unit to conduct welding on the basis of molten pool characteristics fed back visually. Compared with a preset model, parameters such as the welding current, the voltage, the walking speed and the welding gun angle are dynamically adjusted in a closed-loop mode, intelligent self-adaptive control over the welding process is achieved, the welding quality stability and the operation adaptability are improved, and manual dependence is reduced.

Description

Technical Field

[0001] This invention relates to the field of welding automation technology, specifically to an automated welding equipment and method based on visual recognition and molten pool control, applicable to all-position welding of pipes, planes, and complex structures. Background Technology

[0002] Currently, most automated welding equipment uses remote control or preset path control, which lacks flexibility and cannot adapt to complex working conditions. Especially in pipe welding, existing railcars mostly use fixed-direction wheel sets, which cannot turn flexibly, and the wheels are made of hard materials, which are prone to slipping on curved surfaces or pipes, affecting welding accuracy and stability. In addition, traditional welding processes rely on manual experience to adjust current, voltage and welding angle, making it difficult to achieve real-time closed-loop control of welding quality.

[0003] Therefore, there is an urgent need for an intelligent welding equipment and method that can automatically identify weld seams, adjust welding parameters in real time, and adapt to various materials and locations, in order to overcome the shortcomings in current practical applications. Summary of the Invention

[0004] The purpose of this invention is to provide an automated welding device and method to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An automated welding device and method includes a base; a walking mechanism symmetrically arranged on both sides of the base for multi-directional flexible movement of the device; a vision recognition module for real-time acquisition of molten pool images and identification of the molten pool shape, size, and weld position; a welding execution unit including a multi-degree-of-freedom robotic arm and a clamping assembly mounted at its end; a welding unit connected to the clamping assembly for welding the weld; and a control unit disposed inside the base and electrically connected to the walking mechanism, the vision recognition module, and the welding execution unit, wherein the control unit is configured to: control the movement path and speed of the walking mechanism, the posture of the robotic arm, and the welding parameters of the welding unit in real time based on the molten pool image information fed back by the vision recognition module.

[0007] As a further embodiment of the present invention: the walking mechanism includes a connecting frame and Mecanum wheels. The connecting frame is rotatably connected to the base via a rotating shaft. The Mecanum wheels are located at the end of the connecting frame. All Mecanum wheels can be driven independently, and at least the two front wheels have active steering servo control function.

[0008] As a further aspect of the present invention: the surface of the Mecanum wheel is made of a heat-resistant flexible magnetic material.

[0009] As a further aspect of the present invention: the robotic arm in the welding execution unit is a six-axis articulated robotic arm, which drives six joints through six servo motors to realize the movement of the welding torch in six degrees of freedom in space.

[0010] As a further embodiment of the present invention: the welding unit is an electrode arc welding unit or a flux-cored wire gas shielded welding unit; when it is an electrode arc welding unit, it includes an electrode insulation chamber and an electrode held by the clamping assembly, as well as an electrode insulation device; when it is a flux-cored wire gas shielded welding unit, it includes a wire feeder, a wire spool, a shielding gas cylinder, and a welding torch.

[0011] As a further aspect of the present invention: the clamping assembly includes: a clamping frame, which is fixedly connected to the robotic arm; and clamping plates, which are symmetrically arranged inside the clamping frame and connected to the clamping frame at opposite ends via elastic supports, for use in conjunction with the clamping frame to automatically clamp the welding unit.

[0012] As a further aspect of the present invention, the visual recognition module is configured to perform at least one of the following functions: identifying the initial position and direction of the weld; extracting the shape, size and optical features of the weld pool in real time; and determining the welding heat input state and welding quality based on the weld pool features.

[0013] As a further aspect of the present invention, the control unit is configured to: compare the real-time molten pool features acquired by the visual recognition module with a preset ideal molten pool model, and dynamically adjust at least one parameter among welding current, welding voltage, walking mechanism moving speed, robotic arm end welding angle and wire feeding speed according to the comparison result.

[0014] An automated welding method, employing the automated welding equipment described in any of the preceding claims, includes the following steps:

[0015] S1: The visual recognition module identifies and locates the weld seam to be welded.

[0016] S2: Control the movement of the walking mechanism and the robotic arm so that the welding unit is aligned with the welding starting point;

[0017] S3: Welding begins, and images of the molten pool are continuously acquired through the visual recognition module;

[0018] S4: The control unit analyzes the real-time characteristics of the molten pool image and adjusts the welding parameters and equipment motion parameters in real time based on these characteristics;

[0019] S5: Complete welding along the weld seam.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. The use of Mecanum wheels as the walking mechanism, combined with flexible magnetic wheel surfaces, gives the equipment omnidirectional and stable movement and precise positioning capabilities on planes, pipes and complex curved surfaces, greatly expanding the application scenarios;

[0022] 2. Through the core strategy of "visual sensing + real-time closed-loop control", intelligent adaptive adjustment of the welding process is realized. Welding parameters can be dynamically optimized according to the state of the molten pool, which significantly improves the stability and consistency of welding quality and reduces the dependence on operator experience. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of an automated welding equipment.

[0024] Figure 2 This is a schematic diagram of the structure of a robotic arm in an automated welding equipment.

[0025] Figure 3 This is a schematic diagram of the clamping component in an automated welding equipment.

[0026] In the diagram: 1. Base; 2. Connecting frame; 3. Vision recognition module; 4. Mecanum wheel; 5. Welding rod insulation chamber; 6. Mounting seat; 7. Robotic arm; 8. Clamping assembly; 9. Rotary shaft; 10. First motor; 11. First support frame; 12. Second motor; 13. Connecting arm; 14. Second support frame; 15. Third motor; 16. Fourth motor; 17. Third support frame; 18. Fifth motor; 19. Fourth support frame; 20. Sixth motor; 21. Clamping frame; 22. Clamping plate; 23. Elastic bracket. Detailed Implementation

[0027] The technical solution of this application will be further described in detail below with reference to specific embodiments.

[0028] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0029] Please see Figure 1In one embodiment of the present invention, an automated welding device includes: a base 1; a walking mechanism symmetrically arranged on both sides of the base 1 and connected to the base 1 for multi-directional flexible movement of the device; a vision recognition module 3 connected to the walking mechanism for real-time acquisition of molten pool images and identification of the shape, size, and weld position of the molten pool; a welding execution unit including a multi-degree-of-freedom robotic arm 7 and a clamping assembly 8 installed at its end; a welding unit connected to the clamping assembly 8 for cooperating with the adjustment of the robotic arm 7 and the operation of the walking mechanism to complete precise welding of the weld; and a control unit disposed inside the base 1 and electrically connected to the walking mechanism, the vision recognition module 3, and the welding execution unit, wherein the control unit is configured to: control the movement path and speed of the walking mechanism, the posture of the robotic arm 7, and the welding parameters of the welding unit in real time based on the molten pool image information fed back by the vision recognition module 3.

[0030] In one embodiment of the present invention, please refer to Figure 2 The robotic arm 7 includes: a mounting base 6, which is fixedly disposed on the outer side of the top of the base 1; a first motor 10, which is fixedly connected to the mounting base 6, and a first support frame 11 is fixedly disposed on the outer side of its output end; a second motor 12, which is fixedly connected to the first support frame 11, and its output end is fixedly connected to a connecting arm 13, the other end of which is connected to a third motor 15 disposed on the inner side of a second support frame 14; a fourth motor 16, which is fixedly connected to the second support frame 14, and its output end is connected to a third support frame 17 disposed on the outer side of the second support frame 14; a fifth motor 18, which is fixedly connected to the third support frame 17, and its output end is connected to a fourth support frame 19 disposed on the outer side of the third support frame 17, and a sixth motor 20, which is connected to the clamping assembly 8, is fixedly disposed on the inner side of the fourth support frame 19.

[0031] In this embodiment, the robotic arm 7 drives six joints through six servo motors, providing the end effector with complete positioning and orientation capabilities in space. The robotic arm 7 provides flexible spatial movement capabilities, ensuring that the welding torch can be aligned with the weld seam at various positions (flat, horizontal, vertical, and overhead) at the optimal angle.

[0032] In one embodiment of the present invention, please refer to Figure 1 The walking mechanism includes: a connecting frame 2, which is symmetrically arranged on both sides of the base 1, and a rotating shaft 9 that is rotatably connected to the base 1 is fixedly arranged on both sides near the base 1. One rotating shaft 9 is connected to a flipping motor arranged inside the base 1; and Mecanum wheels 4, which are arranged on the outer side of the other end of the connecting frame 2 and connected to the connecting frame 2. All Mecanum wheels 4 can be driven independently, and at least the two front wheels (or all four) have active steering servo control function to optimize the movement path and obstacle crossing performance.

[0033] In one embodiment of the present invention, the surface of the Mecanum wheel 4 is made of a heat-resistant flexible magnetic material.

[0034] In one embodiment of the present invention, please refer to Figure 3 The clamping assembly 8 includes: a clamping frame 21, which is fixedly connected to the output end of the sixth motor 20; and clamping plates 22, which are symmetrically arranged inside the clamping frame 21, with one end of each plate connected to the clamping frame 21 via an elastic bracket 23. These plates are used to cooperate with the clamping frame 21 to clamp and fix the welding unit. The elastic bracket 23 includes a fixed frame fixedly connected to the clamping frame 21 and a sliding rod slidably connected to the fixed frame. A spring is fixedly installed between the sliding rod and the fixed frame. The other end of the sliding rod is fixedly connected to the clamping plate 22. When the welding unit is located between the two clamping plates 22, the welding unit can be automatically clamped.

[0035] In one embodiment of the present invention, the welding unit is either shielded metal arc welding (SMAW) or flux-cored gas shielded welding (FSW). SMAW includes a welding rod insulation chamber 5 and a welding rod fixedly mounted on a base 1. FSW includes a wire feeder, a wire spool, and a protective gas cylinder. The wire feeder continuously and stably pushes the welding wire to the welding torch. The welding unit can be switched according to welding process requirements and cooperates with the vision recognition module 3 and the control unit to achieve adaptive adjustment of welding parameters. In addition, when using SMAW, a welding rod insulation device is also provided to keep the welding rod warm during welding, thereby ensuring welding quality.

[0036] In one embodiment of the present invention, the visual recognition module 3 is configured to perform at least one of the following functions: identifying the initial position and direction of the weld; extracting the shape, size, and optical features of the weld pool in real time; and determining the welding heat input state and welding quality based on the weld pool features. The visual recognition module 3 typically consists of an industrial camera, a lens, and an auxiliary lighting source, and is installed on the outside of a connecting frame 2 to ensure that its field of view is always aligned with the welding arc area. This module mainly undertakes two tasks: first, weld identification and initial positioning before welding; and second, real-time image acquisition of the weld pool during welding. By analyzing the shape, size, brightness, and edge features of the weld pool, the welding heat input, penetration, and the presence of defects such as undercut and weld beads can be indirectly determined.

[0037] In one embodiment of the present invention, the control unit is configured to: compare the real-time molten pool features acquired by the vision recognition module 3 with a preset ideal molten pool model, and dynamically adjust at least one parameter among the following: welding current and / or welding voltage of the welding unit, the moving speed of the walking mechanism, the welding angle at the end of the robotic arm 7, and the wire feeding speed, based on the comparison result. The control unit, acting as the brain of the equipment, is typically composed of an industrial computer or a high-performance PLC. It receives image data from the vision recognition module and runs image processing algorithms and intelligent control algorithms (such as PID control, fuzzy control, etc.). Its core control logic is: comparing the real-time analyzed molten pool features (such as actual area) with the preset "ideal molten pool model" features; if the molten pool is too small, increasing the current or decreasing the walking speed; if the molten pool is too large or collapses, decreasing the current or increasing the walking speed. Simultaneously, it may fine-tune the welding voltage and welding torch angle. Furthermore, the control unit also coordinates the control of the speed vector of the Mecanum wheel 4 to achieve precise path tracking and controls the posture of the robotic arm 7 and the automatic continuation of welding materials.

[0038] An automated welding method, employing the automated welding equipment described in any of the preceding claims, is characterized by comprising the following steps:

[0039] S1. When the equipment approaches the workpiece, the vision recognition module 3 scans the working area and identifies the exact location and direction of the weld through image processing.

[0040] S2, the control unit plans the movement and attitude adjustment path, drives the Mecanum wheel 4 and the robotic arm 7 to move together, precisely move the welding unit to the welding starting point, and adjust it to the appropriate welding angle;

[0041] S3. Arc ignition begins welding. At the same time, the visual recognition module 3 continuously acquires images of the molten pool area at a high frequency (e.g., tens of frames per second).

[0042] S4. The control unit analyzes each frame of image, extracts the features of the molten pool, and adjusts the welding current, voltage, equipment forward speed (Mecanum wheel 4 speed) and welding unit angle (robotic arm 7 joint angle) in real time and dynamically according to the deviation between the features and the target, forming a closed-loop control of "perception-decision-execution" to keep the molten pool in a stable and ideal state at all times.

[0043] S6. Repeat steps S3-S4 until the entire weld seam is completed. After completion, the visual recognition module 3 can be instructed to perform preliminary automated inspection of the weld seam appearance.

[0044] This automated welding equipment uses Mecanum wheels 4 as its walking mechanism, giving the equipment omnidirectional mobility. Combined with flexible magnetic wheel surfaces, it can move stably and flexibly and be precisely positioned on level ground, curved pipe surfaces, and even workpiece surfaces with certain obstacles, greatly expanding its application range. Through "visual sensing + real-time closed-loop control", the welding process is transformed from "open-loop execution" to "closed-loop optimization", which can automatically adapt to changes in workpiece conditions, significantly improving the stability of welding quality and the first-pass yield, and reducing the reliance on skilled welders.

[0045] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention, and these should also be considered within the scope of protection of the present invention. These will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. An automated welding device, characterized in that, include: Base; The walking mechanism is symmetrically arranged on both sides of the base to enable the equipment to move flexibly in multiple directions. The visual recognition module is used to acquire images of the molten pool in real time and identify the shape, size, and weld location of the molten pool. The welding execution unit includes a multi-degree-of-freedom robotic arm and a clamping assembly mounted at its end; A welding unit, which is connected to a clamping assembly, is used to complete the welding of the weld seam; The control unit is located inside the base and is electrically connected to the walking mechanism, the vision recognition module, and the welding execution unit. The control unit is configured to control the movement path and speed of the walking mechanism, the posture of the robotic arm, and the welding parameters of the welding unit in real time based on the molten pool image information fed back by the vision recognition module.

2. The automated welding equipment according to claim 1, characterized in that, The walking mechanism includes a connecting frame and Mecanum wheels. The connecting frame is rotatably connected to the base via a rotating shaft. The Mecanum wheels are located at the end of the connecting frame. All Mecanum wheels can be driven independently, and at least the two front wheels have active steering servo control function.

3. The automated welding equipment according to claim 2, characterized in that, The surface of the Mecanum wheel is made of heat-resistant, flexible magnetic material.

4. The automated welding equipment according to claim 3, characterized in that, The robotic arm in the welding execution unit is a six-axis articulated robotic arm, which uses six servo motors to drive six joints, enabling the welding torch to move in six degrees of freedom in space.

5. The automated welding equipment according to claim 4, characterized in that, The welding unit is either an electrode arc welding unit or a flux-cored wire gas shielded welding unit; when it is an electrode arc welding unit, it includes an electrode insulation chamber and an electrode held by the clamping assembly, as well as an electrode insulation device; when it is a flux-cored wire gas shielded welding unit, it includes a wire feeder, a wire spool, a shielding gas cylinder, and a welding torch.

6. The automated welding equipment according to claim 1, characterized in that, The clamping assembly includes: a clamping frame, which is fixedly connected to the robotic arm; and clamping plates, which are symmetrically arranged inside the clamping frame and connected to the clamping frame at opposite ends via elastic supports, for use in conjunction with the clamping frame to automatically clamp the welding unit.

7. The automated welding equipment according to claim 2, characterized in that, The visual recognition module is configured to perform at least one of the following functions: identify the initial position and direction of the weld; extract the shape, size and optical features of the weld pool in real time; and determine the welding heat input state and welding quality based on the weld pool features.

8. The automated welding equipment and method according to claim 3, characterized in that, The control unit is configured to: compare the real-time molten pool features acquired by the vision recognition module with a preset ideal molten pool model, and dynamically adjust at least one parameter among welding current, welding voltage, walking mechanism moving speed, robotic arm end welding angle and wire feeding speed according to the comparison results.

9. An automated welding method, employing the automated welding equipment as described in any one of claims 1-8, characterized in that, Includes the following steps: S1: The visual recognition module identifies and locates the weld seam to be welded. S2: Control the movement of the walking mechanism and the robotic arm so that the welding unit is aligned with the welding starting point; S3: Welding begins, and images of the molten pool are continuously acquired through the visual recognition module; S4: The control unit analyzes the real-time characteristics of the molten pool image and adjusts the welding parameters and equipment motion parameters in real time based on these characteristics; S5: Complete welding along the weld seam.

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