A fully automatic welding system for light-weight structures

Abstract

This invention provides a fully automated welding system for lightweight structural components, relating to the field of welding technology. The system includes a clamping frame with a horizontally penetrating elongated clamping operation hole. A fixed clamping arm is fixedly installed near one end of the clamping operation hole. This invention utilizes a right-angled double-sided constraint structure, with the fixed clamping arm and movable clamping arm in the clamping frame working in conjunction with the "U"-shaped clamping plate of the clamping head to simultaneously limit the horizontal and vertical positions of a first and second square tube. This ensures that the initial clamping posture of the two square tubes is strictly vertical, solving the welding misalignment problem caused by manual placement. The anti-jamming roller shaft at the end of the movable clamping arm rolls in contact with the vertical side wall of the clamping frame. Combined with the screw drive of the clamping shaft, linear and precise adjustment of the clamping force is achieved, avoiding surface damage or loosening of the square tube caused by friction and jamming in traditional mechanical clamping.

Description

Technical Field

[0001] This invention relates to the field of structural component welding technology, and in particular to a fully automated welding system for lightweight structural components. Background Technology

[0002] In the welding production of lightweight building structural components, vertical butt welding of square tubes is one of the core processes. Traditional welding techniques have long faced the following technical challenges, which severely restrict production efficiency and product quality:

[0003] Insufficient clamping and positioning accuracy: Existing clamping devices mostly adopt a unidirectional constraint structure, which can only fix a single square tube on one side. They lack dual limits in the horizontal and vertical directions, which makes the initial posture of the two tubes easy to deviate, resulting in a high misalignment rate of the joint after welding. Moreover, when connecting long square tubes, the manual calibration operation is cumbersome and inefficient. At the same time, the clamping mechanism is prone to jamming or loosening due to sliding friction, causing scratches on the surface of the square tube or clamping failure.

[0004] Poor fit of joint pressing: Traditional pressing mechanisms use rigid extrusion, which lacks error self-adaptation capability and cannot compensate for minor misalignments between the two pipe joints. This can easily lead to local deformation or stress concentration in the pipe body, resulting in poor weld uniformity and insufficient structural strength.

[0005] Insufficient welding quality stability: The welding torch path relies on manual experience for control, resulting in low movement precision. Furthermore, the open welding environment is susceptible to interference from spatter and airflow, leading to frequent defects such as uneven weld penetration, porosity, and slag inclusions, making it difficult to guarantee consistent welding quality.

[0006] Low level of automation: Clamping, alignment, pressing, welding and other processes are scattered and independent, with poor equipment coordination. They require manual operation step by step, making it impossible to achieve assembly line operation, which seriously limits the efficiency of mass production of lightweight building structural components.

[0007] The aforementioned problems have become a technical bottleneck that urgently needs to be solved in the industry, and there is an urgent need for an integrated and automated welding system to overcome the limitations of existing technologies. Summary of the Invention

[0008] This invention relates to a fully automated welding system for lightweight structural components. Through the fully automated design of clamping, vision alignment, collaborative extrusion, and welding, combined with mechanical transmission, elastic buffering, and visual positioning technology, it achieves high-precision and high-efficiency welding of lightweight building structural components, which is especially suitable for mass production scenarios.

[0009] The present invention provides a full-automatic welding system for a lightweight structural member, which is used to vertically weld a first square pipe and a second square pipe together, and includes: a clamping frame; a long strip-shaped clamping operation hole is horizontally penetrated in the clamping frame, a fixed clamping arm is fixedly installed at a position near one end in the clamping operation hole, and a parallel movable clamping arm is slidably installed at the other end. Symmetrical clamping heads are respectively installed on the fixed clamping arm and the movable clamping arm. The clamping head is a right-angle structure, and the two clamping heads keep the first square pipe and the second square pipe in a vertically welded posture; a welding sleeve box is provided at an angle of 45 degrees on the clamping head towards the weld position. A welding movable hole is penetrated in the welding sleeve box, and a welding torch is arranged in the welding movable hole. The welding torch is connected to an external welding machine; a cooperative cylinder is vertically fixed on one side of the middle part of the clamping frame away from the first square pipe and the second square pipe; an extrusion alignment mechanism is arranged at the upper end of the cooperative cylinder, and the cooperative cylinder drives the extrusion alignment mechanism to extrude and fix the second square pipe and move it closer to the first square pipe; a fixed alignment mechanism is arranged below the cooperative cylinder, and the cooperative cylinder also synchronously drives the fixed alignment mechanism to fix the first square pipe and the welding position of the first square pipe and the second square pipe.

[0010] Optionally, a clamping shaft is rotatably installed between the side walls of the end of the clamping operation hole where the fixed clamping arm and the movable clamping arm are located. A clamping motor is installed on the other side of the fixed clamping arm to drive the clamping shaft to rotate; the part of the clamping shaft connected to the movable clamping arm is a screw rod section. When the clamping shaft rotates, the movable clamping arm moves horizontally in the clamping operation hole. Anti-clamping roller shafts are symmetrically arranged up and down at the end of the movable clamping arm, and the anti-clamping roller shafts are always tangent to the vertical side wall of the clamping frame.

[0011] Optionally, an operation handle rod is also fixedly installed on one side of the clamping frame where the cooperative cylinder is located. The operation handle rod is parallel to the clamping frame, and a control box is arranged on the operation handle rod.

[0012] Optionally, "U"-shaped clamping plates are respectively arranged at the two right-angle ends of the clamping head, and the two clamping plates are respectively used to clamp the first square pipe and the second square pipe to keep them in a perpendicular posture.

[0013] Optionally, card rails along the welding movable hole are arranged on the outer walls at the upper ends of the two sides of the welding sleeve box. On the welding sleeve box at the upper card rail, parallel tooth rails are also arranged; the welding torch is vertically and slidably connected to a sliding seat. The sliding seat is slidably clamped on the two card rails. A gear is also rotatably installed at the upper end of the sliding seat. The gear meshes with the tooth rail. A sliding motor for driving it to rotate is also installed on the sliding seat at the upper end of the gear. A tension spring is connected between the end of the welding torch and the sliding seat. The tension spring provides a downward pulling force for the welding torch all the time. During welding, the sliding motor works, and through the meshing of the gear and the tooth rail, the sliding seat slides, and the welding torch moves along with it to weld the joint of the first square pipe and the second square pipe.

[0014] Optionally, an extended coordinating plate is vertically fixedly connected to the end of the piston rod of the coordinating cylinder, and the coordinating plate is simultaneously connected to the extrusion and mating mechanism and the fixed alignment mechanism.

[0015] Optionally, the extrusion mating mechanism consists of an extrusion guide rod, an inner retaining ring, a first spring, a fixed sleeve, a connecting arm, and an extrusion block. The extrusion guide rod is vertically and slidably mounted on the cooperating cylinder via the fixed sleeve. One end of the extrusion guide rod near the second square tube is rotatably connected to the connecting arm via a pin. The other end of the connecting arm is rotatably connected to the extrusion block via a pin. The extrusion block has a triangular block structure. The other corner of the extrusion block near the connecting arm is rotatably connected to the clamping frame via a pin. The side of the extrusion block that contacts the second square tube is a non-slip frosted surface. The other end of the extrusion guide rod is vertically and slidably connected to the cooperating plate. An inner retaining ring is fixed on the extrusion guide rod between the cooperating plate and the fixed sleeve. A first spring is fitted on the extrusion guide rod between the inner retaining ring and the cooperating plate. When the cooperating plate moves towards the second square tube, the extrusion guide rod moves synchronously. The connecting arm drives the outer corner of the extrusion block to contact the second square tube first. During continuous movement, the extrusion block rotates downward around the pin rotatably connected to the clamping frame as the axis of rotation, further mating the second square tube with the first square tube.

[0016] Optionally, the fixed alignment mechanism comprises a brake block, an alignment target hole, a vision camera, a side pressure buffer seat, a buffer rod, a traveling wheel frame, a second spring, rollers, and a traveling motor. The brake block is fixedly connected to the coordination plate. One end of the brake block that contacts the first square tube has a cross-shaped alignment target hole, and the other end of the brake block has a vision camera that captures the marked position on the first square tube through the alignment target hole. Side pressure buffer seats are respectively provided on the left and right sides of the brake block. Two symmetrical buffer rods are vertically arranged on the side pressure buffer seats. A traveling wheel frame is fixedly arranged at the end of the buffer rods. Rollers are rotatably mounted on the traveling wheel frame. The rollers are connected to the first square tube. When the tubes come into contact, a second spring is mounted on the buffer rod to provide a thrust for the rollers to move closer to the first square tube. The upper end of the walking wheel frame is also equipped with a walking motor, which drives the rollers to rotate. During welding, the device is snapped onto the first and second square tubes. The visual camera collects the accuracy of the marked position through the alignment target hole. If it is not accurate, the walking motor works, driving the device and the second square tube to move to the marked position on the first square tube. The cooperating cylinder works, and the squeezing and mating mechanism further fixes the second square tube and aligns it with the first square tube. The brake block contacts and squeezes the first square tube to fix it. The second spring is compressed, the sliding motor works, and the welding torch moves to weld the joint.

[0017] This invention provides a fully automated welding system for lightweight structural components, which has the following advantages:

[0018] This invention utilizes a clamping frame with a fixed clamping arm and a movable clamping arm, along with a clamping head featuring a "U"-shaped clamping plate. This right-angled double-sided constraint structure synchronously limits the horizontal and vertical positioning of the first and second square tubes, ensuring a strictly vertical initial clamping posture and resolving the welding misalignment problem caused by manual placement. The anti-jamming roller shaft at the end of the movable clamping arm rolls in contact with the vertical sidewall of the clamping frame. Combined with the screw drive of the clamping shaft, this achieves linear and precise adjustment of the clamping force, avoiding surface damage or loosening of the square tubes caused by friction and jamming in traditional mechanical clamping.

[0019] The fixed alignment mechanism, through the cooperation of the cross-shaped alignment target hole on the brake block and the vision camera, captures the marked position of the first square tube in real time. Combined with the walking motor driving the roller to move along the surface of the square tube, it realizes the automatic position correction of the second square tube. The elastic buffer system composed of the second spring and the buffer rod can absorb vibration during movement and maintain a constant contact pressure between the roller and the square tube, solving the technical problems of low efficiency and poor accuracy of manual adjustment. It is especially suitable for the multi-point welding positioning needs of long square tubes.

[0020] The extrusion and mating mechanism employs the lever principle of a triangular extrusion block and connecting arm. Driven by a cooperating cylinder, it gradually applies pressure and flips the anti-slip frosted surface to flexibly press the second square tube against the first square tube. The combination design of the first spring and the inner retaining ring can adaptively absorb the slight misalignment of the joint between the two square tubes, avoiding tube deformation or stress concentration caused by rigid extrusion, ensuring a uniform and tight joint, and significantly improving welding strength and appearance quality.

[0021] The 45° tilt design of the welding sleeve allows the welding torch to be precisely aligned with the V-shaped weld. The sliding motor drives the welding torch to move at a constant speed along a preset path through the meshing of gears and a toothed rail. Combined with the constant downward pressure provided by the tension spring, this ensures arc stability and consistent penetration depth during the welding process. The enclosed structure of the welding sleeve effectively isolates sparks, reducing safety hazards and minimizing external environmental interference with welding quality. It also solves the defects such as porosity and slag inclusions that are prone to occur in traditional open welding.

[0022] The collaborative cylinder synchronously drives the extrusion and alignment mechanism and the fixed alignment mechanism through a collaborative plate, realizing a streamlined operation of clamping, positioning, alignment adjustment, joint pressing, and welding fixation. The integrated design of the operating lever and control box simplifies human-machine interaction, allowing operators to quickly complete equipment clamping, parameter setting, and process monitoring. The entire system, through the deep integration of mechanical transmission, elastic buffering, and automated control, integrates traditional multi-process welding into a single-clamping full-process operation, significantly shortening the welding time per piece, making it particularly suitable for the mass production needs of lightweight building structural components. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments will be briefly described below.

[0024] The accompanying drawings described below are only related to some embodiments of the invention and are not intended to limit the invention.

[0025] In the attached diagram:

[0026] Figure 1 is a three-dimensional structural diagram of an embodiment of the present invention. Figure 1 ;

[0027] Figure 2 is a three-dimensional structural diagram of an embodiment of the present invention. Figure 2 ;

[0028] Figure 3 is a schematic diagram of the first and second square tubes in an unclamped state according to an embodiment of the present invention.

[0029] Figure 4 is an axial view of the clamping head and clamping frame in a separated state according to an embodiment of the present invention;

[0030] Figure 5 is an axial view of the welding torch and welding sleeve in a separated state according to an embodiment of the present invention;

[0031] Figure 6 is an enlarged structural diagram of part A in Figure 5;

[0032] Figure 7 is an axial view of the movable clamping arm and clamping frame in a separated state according to an embodiment of the present invention;

[0033] Figure 8 is a schematic diagram of the combined axial view of the collaborative cylinder, extrusion and alignment mechanism and the fixed alignment mechanism according to an embodiment of the present invention.

[0034] Figure label:

[0035] 1-First square tube; 2-Second square tube; 3-Clamping frame; 301-Clamping operation hole; 302-Fixed clamping arm; 303-Modible clamping arm; 3031-Anti-jamming roller shaft; 304-Clamping motor; 305-Clamping shaft; 3051-Screw section; 4-Operating lever; 401-Control box; 5-Clamping head; 501-Clamping plate; 6-Welding sleeve; 601-Welding movable hole; 602-Clamping rail; 603-Welding torch; 604-Gear rail; 605-Sliding seat; 606-Tension spring; 607-Slide rail 608-Motor; 7-Gear; 7-Cooperating cylinder; 701-Cooperating plate; 8-Extrusion mating mechanism; 801-Extrusion guide rod; 802-Inner retaining ring; 803-First spring; 804-Fixed sleeve block; 805-Connecting arm; 806-Extrusion block; 9-Fixed alignment mechanism; 901-Brake block; 902-Alignment target hole; 903-Vision camera; 904-Side pressure buffer seat; 905-Buffer rod; 906-Walking wheel frame; 907-Second spring; 908-Roller; 909-Walking motor. Detailed Implementation

[0036] 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.

[0037] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0038] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0040] The embodiments thereof are described in detail below based on the overall concept of the present invention.

[0041] Example 1: Please refer to Figures 1 to 8 :

[0042] The present invention provides a full-automatic welding system for lightweight structural members, which is used to vertically weld a first square pipe 1 and a second square pipe 2 together. The system includes: a clamping frame 3; a long strip-shaped clamping operation hole 301 is horizontally penetrated through the clamping frame 3. At a position close to one end in the clamping operation hole 301, a fixed clamping arm 302 is fixedly installed, and a parallel movable clamping arm 303 is slidably installed at the other end. Symmetric clamping heads 5 are respectively installed on the fixed clamping arm 302 and the movable clamping arm 303. The clamping head 5 is a right-angle structure, and the two clamping heads 5 hold the first square pipe 1 and the second square pipe 2 in a vertically welded posture; on the clamping head 5, a welding sleeve box 6 is provided at a position inclined at 45 degrees towards the weld position. A welding activity hole 601 is penetrated through the welding sleeve box 6, and a welding torch 603 is provided in the welding activity hole 601. The welding torch 603 is connected to an external welding machine; on one side of the middle part of the clamping frame 3 far away from the first square pipe 1 and the second square pipe 2, a cooperative cylinder 7 is vertically fixed; at the upper end of the cooperative cylinder 7, a squeezing and aligning mechanism 8 is provided. The cooperative cylinder 7 drives the squeezing and aligning mechanism 8 to squeeze and fix the second square pipe 2 and move it closer to the first square pipe 1; below the cooperative cylinder 7, a fixed alignment mechanism 9 is provided. The cooperative cylinder 7 also synchronously drives the fixed alignment mechanism 9 to fix the first square pipe 1 and the welding position of the first square pipe 1 and the second square pipe 2.

[0043] Wherein, a clamping shaft 305 is rotatably installed between the side wall of the end of the clamping operation hole 301 where the fixed clamping arm 302 and the movable clamping arm 303 are located. On the other side of the fixed clamping arm 302, a clamping motor 304 is installed to drive the clamping shaft 305 to rotate; the part of the clamping shaft 305 connected to the movable clamping arm 303 is a screw rod section 3051. When the clamping shaft 305 rotates, the movable clamping arm 303 moves horizontally in the clamping operation hole 301. Anti-clamping roller shafts 3031 are symmetrically arranged up and down at the end of the movable clamping arm 303, and the anti-clamping roller shafts 3031 are always tangent to the vertical side wall of the clamping frame 3.

[0044] Wherein, on one side of the clamping frame 3 where the cooperative cylinder 7 is located, an operation handle rod 4 is also fixedly installed. The operation handle rod 4 is parallel to the clamping frame 3, and a control box 401 is provided on the operation handle rod 4.

[0045] Wherein, at the two right-angle ends of the clamping head 5, "C"-shaped clamping plates 501 are respectively provided, and the two clamping plates 501 are respectively used to clamp the first square pipe 1 and the second square pipe 2 to keep them in a perpendicular posture.

[0046] The welding sleeve 6 has two outer walls at the upper end with guide rails 602 along the welding movable hole 601. The welding sleeve 6 at the upper guide rail 602 is also provided with a parallel toothed rail 604. The welding torch 603 is vertically and slidably connected to the sliding seat 605. The sliding seat 605 is slidably engaged with the two guide rails 602. A gear 608 is rotatably installed at the upper end of the sliding seat 605. The gear 608 meshes with the toothed rail 604. A sliding motor 607 for driving its rotation is also installed on the sliding seat 605 at the upper end of the gear 608. A tension spring 606 is connected between the end of the welding torch 603 and the sliding seat 605. The tension spring 606 provides the welding torch 603 with a downward pulling force. During welding, the sliding motor 607 works. Through the meshing of the gear 608 and the toothed rail 604, the sliding seat 605 slides, and the welding torch 603 moves accordingly to weld the joint of the first square tube 1 and the second square tube 2.

[0047] Among them, the piston rod end of the cooperating cylinder 7 is vertically fixedly connected to an extended cooperating plate 701, which is simultaneously connected to the extrusion and alignment mechanism 8 and the fixed alignment mechanism 9.

[0048] The extrusion mating mechanism 8 consists of an extrusion guide rod 801, an inner retaining ring 802, a first spring 803, a fixed sleeve 804, a connecting arm 805, and an extrusion block 806. The extrusion guide rod 801 is vertically and slidably mounted on the cooperating cylinder 7 via the fixed sleeve 804. One end of the extrusion guide rod 801 near the second square tube 2 is rotatably connected to the connecting arm 805 via a pin. The other end of the connecting arm 805 is rotatably connected to the extrusion block 806 via a pin. The extrusion block 806 has a triangular block structure. The other corner of the extrusion block 806 near the connecting arm 805 is rotatably connected to the clamping frame 3 via a pin. The side of the extrusion block 806 that contacts the second square tube 2 is a non-slip frosted surface. The other end of the extrusion guide rod 801 is vertically slidably connected to the cooperating plate 701. An inner retaining ring 802 is fixedly provided on the extrusion guide rod 801 between the cooperating plate 701 and the fixed sleeve block 804. A first spring 803 is fitted on the extrusion guide rod 801 between the inner retaining ring 802 and the cooperating plate 701. When the cooperating plate 701 moves to the side of the second square tube 2, the extrusion guide rod 801 moves synchronously. Through the connecting arm 805, the outer corner of the extrusion block 806 is driven to contact the second square tube 2 first. During the continuous movement, the extrusion block 806 rotates downward around the pin shaft rotatably connected to the clamping frame 3 as the rotation axis to further align the second square tube 2 with the first square tube 1.

[0049] The fixed alignment mechanism 9 comprises a brake block 901, an alignment target hole 902, a vision camera 903, a side pressure buffer seat 904, a buffer rod 905, a traveling wheel frame 906, a second spring 907, a roller 908, and a traveling motor 909. The brake block 901 is fixedly connected to the coordination plate 701. One end of the brake block 901 that contacts the first square tube 1 is provided with a cross-shaped alignment target hole 902, and the other end of the brake block 901 is provided with a vision camera 903 that captures the marked position on the first square tube 1 through the alignment target hole 902. Side pressure buffer seats 904 are provided on the left and right sides of the brake block 901, and two symmetrical buffer rods 905 are vertically arranged on the side pressure buffer seats 904. The end of the buffer rod 905 is fixedly provided with a traveling wheel frame 906, and a roller 908 is rotatably mounted on the traveling wheel frame 906. Roller 908 contacts the first square tube 1. A second spring 907 is mounted on the buffer rod 905 to provide a thrust for roller 908 to move closer to the first square tube 1. The upper end of the walking wheel frame 906 is also equipped with a walking motor 909, which is used to drive roller 908 to rotate. During welding, the device is snapped onto the first square tube 1 and the second square tube 2. The vision camera 903 collects whether the marked position is accurate through the alignment target hole 902. If it is not accurate, the walking motor 909 works, driving the device and the second square tube 2 to move to the marked position of the first square tube 1. The cooperating cylinder 7 works, and the pressing and aligning mechanism 8 further fixes the second square tube 2 and aligns it with the first square tube 1. The brake block 901 contacts and presses and fixes the first square tube 1. The second spring 907 is compressed, the sliding motor 607 works, and the welding gun 603 moves to weld the joint.

[0050] The following provides further explanation and elaboration on the structural and technical features mentioned above:

[0051] The clamping frame 3 serves as the main frame, with a fixed clamping arm 302 and a movable clamping arm 303 connected via a clamping shaft 305 within its clamping operation hole 301. When the lead screw section 3051 of the clamping shaft 305 rotates under the drive of the clamping motor 304, the movable clamping arm 303 moves horizontally along the clamping operation hole 301, cooperating with the right-angle clamping head 5 of the fixed clamping arm 302 to achieve vertical clamping and fixation of the first square tube 1 and the second square tube 2. The "U"-shaped clamping plate 501 of the clamping head 5 simultaneously constrains the horizontal and vertical directions of the two square tubes through double right-angle surfaces, ensuring a vertical posture before welding. The anti-jamming roller shaft 3031 at the end of the movable clamping arm 303 maintains tangential rolling contact with the vertical sidewall of the clamping frame 3, reducing sliding friction and preventing movement jamming.

[0052] The welding box 6 is designed with a 45° inclination to align the welding torch 603 directly with the weld position of the seam between the two square tubes. The sliding seat 605 meshes with the tooth rail 604 through the gear 608 and moves along the clamping rail 602 under the drive of the sliding motor 607, driving the welding torch 603 to complete continuous welding actions. The tension spring 606 provides a constant downward pressure for the welding torch 603 to ensure stable contact between the welding torch and the weld during the welding process. The closed structure of the welding box 6 can limit the range of welding spatter and enhance safety;

[0053] The collaborative cylinder 7 synchronously controls the extrusion alignment mechanism 8 and the fixed alignment mechanism 9 through the collaborative plate 701. In the extrusion alignment mechanism 8, when the collaborative cylinder 7 pushes the collaborative plate 701, the extrusion guide rod 801 drives the connecting arm 805 to make the triangular extrusion block 806 rotate around the pin shaft on the clamping bracket 3, and its anti-slip abrasive surface gradually compresses the second square tube 2, forcing the seams of the two square tubes to fit tightly. The first spring 803 absorbs displacement errors during the extrusion process to avoid rigid impacts. The brake block 901 of the fixed alignment mechanism 9 cooperates with the visual camera 903 through the cross alignment target hole 902 to identify the marked position on the first square tube 1 in real time. If there is a position deviation, the traveling motor 909 drives the roller 908 to move along the first square tube 1, and the pressure is buffered and adjusted through the second spring 907 until visual alignment is completed. The brake block 901 finally compresses the first square tube 1, forming a double fixation in cooperation with the elastic support of the roller 908;

[0054] The operating handle 4 and the control box 401 are integrated on the side of the clamping bracket 3, facilitating manual operation and adjustment of welding parameters; the segmented design of the clamping shaft 305, with the screw rod section 3051 and the ordinary shaft section, enables precise linear drive of the movable clamping arm 303 while avoiding structural interference.

[0055] The clamping bracket 3 is welded and formed from Q235 steel plate, with a length of 800 mm, a width of 150 mm, and a thickness of 50 mm. The length of the clamping operation hole 301 is 600 mm and the width is 80 mm, suitable for square tubes with side lengths of 50 - 100 mm;

[0056] Both the fixed clamping arm 302 and the movable clamping arm 303 are machined from 45# steel, with a thickness of 40 mm. The inner wall of the "匚"-shaped clamping plate 501 of the clamping head 5 is provided with a polyurethane anti-slip lining, and the opening width of the clamping plate is 2 mm wider than the side length of the suitable square tube, ensuring firm clamping without damaging the tube body;

[0057] The screw rod section 3051 of the clamping shaft 305 uses a trapezoidal thread with a pitch of 5 mm. The clamping motor 304 is a stepper motor with a rated power of 500 W, capable of achieving stepless adjustment of the clamping force from 0 - 500 N;

[0058] The welding housing 6 is made of stainless steel. The width of the internal welding movable hole 601 is 30mm, the length of the guide rail 602 is 300mm, the module of the toothed rail 604 is 2, and the sliding motor 607 is a servo motor with a speed adjustment range of 0-50r / min to ensure that the welding torch moving speed is uniform and controllable.

[0059] The cylinder 7 has a diameter of 50mm, a stroke of 100mm, and a working pressure of 0.4-0.8MPa. The elastic coefficients of the first spring 803 and the second spring 907 are 5N / mm and 3N / mm, respectively, to meet the compression buffering requirements of square tubes of different specifications.

[0060] The visual camera 903 has a resolution of 1920×1080, a frame rate of 30fps, and an alignment accuracy of ±0.1mm. The walking motor 909 is a DC geared motor with a rated speed of 30r / min, which, together with the roller 908, enables the device to move smoothly.

[0061] Working principle: The operator places the first square tube 1 and the second square tube 2 into the two right-angle clamping plates 501 of the clamping head 5 respectively (or directly holds the first square tube 1 and the second square tube 2 in the assembled state by hand), and starts the clamping motor 304 through the control box 401. The lead screw section 3051 of the clamping shaft 305 rotates under the drive of the motor, driving the movable clamping arm 303 to move horizontally along the clamping operation hole 301, forming a symmetrical clamping force in conjunction with the fixed clamping arm 302. The anti-jamming roller shaft 3031 at the end of the movable clamping arm 303 rolls into contact with the vertical side wall of the clamping frame 3 to ensure smooth movement without jamming. The "U"-shaped clamping plates 501 of the two clamping heads 5 initially fix the first square tube 1 and the second square tube 2 into a vertical position through right-angle constraints. At this time, a V-shaped weld seam to be welded is formed at the joint of the ends of the two square tubes.

[0062] After clamping is completed, the coordinating cylinder 7 is activated, and its piston rod synchronously pushes the squeezing and aligning mechanism 8 and the fixing and aligning mechanism 9 through the coordinating plate 701. The brake block 901 of the fixing and aligning mechanism 9 moves with the coordinating plate 701, and its cross-shaped alignment target hole 902 aligns with the preset mark on the first square tube 1. The vision camera 903 records the alignment status in real time. If a positional offset is detected between the second square tube 2 and the mark on the first square tube 1, the control box 401 triggers the walking motor 909 to drive the roller 908 to rotate, causing the entire clamping frame 3 and the second square tube 2 to move along the surface of the first square tube 1. The roller 908 is pressed tightly against the surface of the square tube by the elastic pressure of the second spring 907, and the buffer rod 905 absorbs the vibration during the movement until the vision camera 903 confirms that the alignment target hole 902 is completely aligned with the mark, thus completing the precise positioning.

[0063] After alignment, the coordinating cylinder 7 continues to push the coordinating plate 701 towards the second square tube 2. The extrusion guide rod 801 of the extrusion mating mechanism 8 moves forward with the coordinating plate 701, driving the triangular extrusion block 806 to rotate around the pin on the clamping frame 3 via the connecting arm 805. The anti-slip frosted surface of the extrusion block 806 first contacts the surface of the second square tube 2 at an inclined angle. As the cylinder continues to apply pressure, the extrusion block 806 gradually flips downward, pressing the second square tube 2 against the first square tube 1, ensuring that the joint between the two square tubes is completely fitted. During this process, the first spring 803 absorbs mechanical errors through the compression deformation between the inner retaining ring 802 and the coordinating plate 701, avoiding deformation or displacement of the square tube caused by rigid extrusion. At the same time, the brake block 901 presses the surface of the first square tube 1 with the thrust of the coordinating cylinder 7, and forms a two-way fixation with the elastic support of the roller 908, further locking the position of the two square tubes.

[0064] After the joint is aligned and fixed, the sliding motor 607 inside the welding housing 6 starts, driving the gear 608 to mesh along the gear rail 604, which in turn drives the sliding seat 605 to move at a constant speed along the clamping rail 602. The welding torch 603 maintains stable contact with the weld seam through the continuous downward force of the tension spring 606, and moves along the 45° inclined welding movable hole 601 under the traction of the sliding seat 605, completing the continuous welding of the V-shaped joint. The closed structure of the welding housing 6 effectively blocks spatter, and the welding torch movement path is precisely matched with the joint direction, ensuring a uniform and firm weld seam. During the welding process, the control box 401 monitors the welding parameters in real time, and the operator can adjust the welding speed or pause the operation through the operating lever 4.

[0065] After welding is completed, the coordinating cylinder 7 retracts in the reverse direction, and the pressing block 806 of the pressing and aligning mechanism 8 resets and releases the second square tube 2 under the action of the connecting arm 805. Simultaneously, the brake block 901 and roller 908 of the fixed alignment mechanism 9 disengage from the surface of the first square tube 1. The clamping motor 304 drives the clamping shaft 305 to reverse, and the movable clamping arm 303 returns to its initial position, allowing the operator to easily remove the welded vertical structural component. After all mechanisms in the system reset, the next welding cycle of the square tubes can begin.

[0066] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A fully automated welding system for lightweight building structural components, used for vertically welding a first square tube (1) and a second square tube (2) together, characterized in that, include: Clamping frame (3); a long strip-shaped clamping operation hole (301) is horizontally penetrated in the clamping frame (3), a fixed clamping arm (302) is fixedly installed at a position close to one end in the clamping operation hole (301), and a parallel movable clamping arm (303) is slidably installed at the other end. Symmetric clamping heads (5) are respectively installed on the fixed clamping arm (302) and the movable clamping arm (303). The clamping head (5) is of a right-angle structure, and the two clamping heads (5) keep the first square pipe (1) and the second square pipe (2) in a perpendicular posture to be welded; a welding sleeve box (6) is arranged at an angle of 45 degrees on the clamping head (5) towards the weld position. A welding activity hole (601) is penetrated in the welding sleeve box (6), and a welding torch (603) is arranged in the welding activity hole (601). The welding torch (603) is connected to an external welding machine; a cooperative cylinder (7) is vertically fixed on one side of the middle part of the clamping frame (3) far away from the first square pipe (1) and the second square pipe (2); an extrusion alignment mechanism (8) is arranged at the upper end of the cooperative cylinder (7), and the cooperative cylinder (7) drives the extrusion alignment mechanism (8) to extrude and fix the second square pipe (2) and move it closer to the first square pipe (1); a fixed alignment mechanism (9) is arranged below the cooperative cylinder (7), and the cooperative cylinder (7) also synchronously drives the fixed alignment mechanism (9) to fix the first square pipe (1) and the welding position of the first square pipe (1) and the second square pipe (2); "U"-shaped clamping plates (501) are respectively arranged at the two right-angle ends of the clamping head (5), and the two clamping plates (501) are respectively used for clamping the first square pipe (1) and the second square pipe (2) to keep them in a perpendicular posture; the end of the piston rod of the cooperative cylinder (7) is vertically and fixedly connected with an extended cooperative plate (701), and the cooperative plate (701) is simultaneously connected with the extrusion alignment mechanism (8) and the fixed alignment mechanism (9);The extrusion mating mechanism (8) consists of an extrusion guide rod (801), an inner retaining ring (802), a first spring (803), a fixed sleeve (804), a connecting arm (805), and an extrusion block (806). The extrusion guide rod (801) is vertically slidably mounted on the cooperating cylinder (7) via the fixed sleeve (804). One end of the extrusion guide rod (801) near the second square tube (2) is rotatably connected to the connecting arm (805) via a pin. The other end of the connecting arm (805) is rotatably connected to the extrusion block (806) via a pin. The extrusion block (806) has a triangular block structure. The other corner of the extrusion block (806) near the connecting arm (805) is rotatably connected to the clamping frame (3) via a pin. The side facing the second square tube (2) is a non-slip frosted surface. The other end of the extrusion guide rod (801) is vertically slidably connected to the coordinating plate (701). An inner retaining ring (802) is fixedly provided on the extrusion guide rod (801) between the coordinating plate (701) and the fixed sleeve block (804). A first spring (803) is fitted on the extrusion guide rod (801) between the inner retaining ring (802) and the coordinating plate (701). When the coordinating plate (701) moves towards the second square tube (2), the extrusion guide rod (801) moves synchronously. Through the connecting arm (805), the outer corner of the extrusion block (806) first contacts the second square tube (2). During the continuous movement, the extrusion block (806) is rotatably connected to the clamping frame. (3) The pin on the rotating axis flips downward to squeeze the second square tube (2) and the first square tube (1) to further align; the fixed alignment mechanism (9) is composed of a brake block (901), an alignment target hole (902), a vision camera (903), a side pressure buffer seat (904), a buffer rod (905), a walking wheel frame (906), a second spring (907), a roller (908), and a walking motor (909). The brake block (901) is fixedly connected to the cooperating plate (701). One end of the brake block (901) that contacts the first square tube (1) is provided with a cross-shaped alignment target hole (902), and the other end of the brake block (901) is provided with a vision camera (903) facing the alignment target hole (902). 2) The marked position on the first square tube (1) is photographed; the brake block (901) is provided with side pressure buffer seats (904) on the left and right sides respectively, and two symmetrical buffer rods (905) are vertically provided on the side pressure buffer seats (904). The end of the buffer rod (905) is fixed with a walking wheel frame (906). A roller (908) is rotatably installed on the walking wheel frame (906). The roller (908) is in contact with the first square tube (1). A second spring (907) is fitted on the buffer rod (905) to provide a thrust for the roller (908) to move closer to the first square tube (1). The upper end of the walking wheel frame (906) is also provided with a walking motor (909), which is used to drive the roller (908) to rotate.

2. The fully automated welding system for lightweight building structural components according to claim 1, characterized in that: A clamping shaft (305) is rotatably installed between the fixed clamping arm (302) and the side wall of the clamping operation hole (301) where the movable clamping arm (303) is located. A clamping motor (304) is installed on the other side of the fixed clamping arm (302) to drive the clamping shaft (305) to rotate. The part of the clamping shaft (305) connected to the movable clamping arm (303) is a lead screw section (3051). When the clamping shaft (305) rotates, the movable clamping arm (303) moves horizontally in the clamping operation hole (301). Anti-jamming roller shafts (3031) are symmetrically provided at the ends of the movable clamping arm (303). The anti-jamming roller shafts (3031) are always tangent to the vertical side wall of the clamping frame (3).

3. The fully automated welding system for lightweight building structural components according to claim 1, characterized in that: An operating lever (4) is also fixedly provided on the side where the cooperating cylinder (7) is located on the clamping frame (3). The operating lever (4) is parallel to the clamping frame (3), and a control box (401) is provided on the operating lever (4).

4. The fully automated welding system for lightweight building structural components according to claim 1, characterized in that: The upper two outer walls of the welding sleeve (6) are provided with guide rails (602) along the welding movable hole (601), and the welding sleeve (6) at the upper guide rail (602) is also provided with a parallel toothed rail (604); the welding torch (603) is vertically and slidably connected to the sliding seat (605), the sliding seat (605) is slidably engaged on the two guide rails (602), and a gear (608) is rotatably installed on the upper end of the sliding seat (605), the gear (608) meshes with the toothed rail (604), and the gear (608) meshes with the toothed rail (604). 08) A sliding motor (607) for driving its rotation is also installed on the upper sliding seat (605). A tension spring (606) is connected between the end of the welding torch (603) and the sliding seat (605). The tension spring (606) provides the welding torch (603) with a downward pulling force. When welding, the sliding motor (607) works and meshes with the gear (604) through the gear (608). The sliding seat (605) slides and the welding torch (603) moves accordingly to weld the joint of the first square tube (1) and the second square tube (2).

5. The fully automated welding system for lightweight building structural components according to claim 4, characterized in that: During welding, the welding system is attached to the first square tube (1) and the second square tube (2). The vision camera (903) collects whether the marked position is accurate through the alignment target hole (902). If it is not accurate, the walking motor (909) works, driving the welding system and the second square tube (2) to move to the marked position of the first square tube (1). The cooperating cylinder (7) works, and the squeezing and mating mechanism (8) further fixes the second square tube (2) and aligns it with the first square tube (1). The brake block (901) contacts and squeezes and fixes the first square tube (1). The second spring (907) is compressed, the sliding motor (607) works, and the welding gun (603) moves to weld the joint.

Images