Laser welding and weld detection integrated apparatus and method
By integrating laser welding and weld inspection into a single device, the problem caused by the separation of welding and inspection in traditional equipment is solved, achieving efficient and accurate welding and inspection, adapting to multiple specifications and complex weld scenarios, and improving automation and safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JILIN UNIVERSITY
- Filing Date
- 2026-03-17
- Publication Date
- 2026-05-19
AI Technical Summary
Existing laser welding equipment separates welding and inspection functions, resulting in time-consuming transportation, low accuracy, poor equipment adaptability, insufficient automation, and inadequate safety and quality control. Traditional equipment also suffers from problems such as single function, low efficiency, and lagging inspection.
An integrated laser welding and weld inspection device was designed, which integrates laser welding, weld inspection, clamping, pressing and pushing devices. The module space can be flexibly adjusted through multiple sets of slider guide rails and pneumatic and electric transmission devices. Combined with photoelectric sensor for precise positioning and 3D vision camera for all-dimensional detection, it can achieve efficient and accurate welding and inspection.
It achieves highly efficient automation of multi-specification welding and complex weld inspection, reduces the impact of human factors, ensures stable and consistent welding quality, adapts to the diverse production needs of multiple industries, and improves production efficiency and safety.
Smart Images
Figure CN121847964B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of laser welding, and particularly relates to an integrated device and method for laser welding and weld seam detection with high adaptability. It is mainly used for the automated welding processing and real-time quality monitoring of complex curved surfaces, variable thickness or multi-layer materials in the mechanical manufacturing fields such as aerospace and new energy vehicles. Background Art
[0002] Laser welding utilizes high-energy laser pulses to locally heat materials in a tiny area. The energy of laser radiation diffuses into the interior of the materials through heat conduction, melting the materials to form a specific molten pool to achieve the purpose of welding. Weld quality inspection is a crucial link in welding engineering, and the weld quality directly relates to structural integrity, safety performance, and service life. In industrial fields such as pressure vessels, pipeline systems, bridge construction, shipbuilding, aerospace, and nuclear facilities, welded joints are often the weak links of the structure. Tiny defects such as cracks, pores, and slag inclusions may expand under the action of stress, leading to catastrophic failures. Weld quality inspection is not only a necessary step in the manufacturing process but also a key technical measure to prevent accidents and ensure the safety of life and property.
[0003] Most traditional devices are designed with separate welding and detection functions, and workpieces need to be transported manually or by additional devices, which not only increases time and labor costs but also easily affects the accuracy due to transportation deviation. Moreover, traditional devices have poor adaptability, and the welding and clamping structures are mostly fixed. Facing workpieces of different specifications and categories, frequent shutdowns are required for debugging, making it difficult to adapt to multi-variety production. At the same time, traditional devices have low levels of automation and intelligence, relying on manual labor to complete processes such as loading and positioning, parameter adjustment, and result judgment. It is easy to cause unstable accuracy, missed or false detections due to human factors, and lacks real-time linkage control.
[0004] For example, in the patent with the publication number CN110421260A, although the device realizes the welding and detection functions of lithium battery tabs, its welding versatility is poor, the adjustment dimensions are limited, and its adaptability is weak when facing complex weld seam scenarios. At the same time, the device does not have a clamping or welding parameter module that can be flexibly adjusted, making it difficult to adapt to laser welding of workpieces with different thicknesses and materials. In the patent with the publication number CN219684343U, although the device integrates the electronic control system, system host, and integrated laser in the frame to realize the independent operation of the device outside the mold, it does not involve all-process automation modules such as workpiece transfer, detection, and recycling, and needs to cooperate with other devices to complete the complete production process. In the patent with the publication number CN223070649U, the device is based on a workbench, and the clamping unit and welding unit are modularly arranged, which is convenient for installation and disassembly. However, its detection dimension is single, the accuracy is limited, and only the welding firmness is detected through compressive testing, lacking full-dimensional weld seam detection means and unable to identify subtle defects such as surface cracks and pores in the weld seam, resulting in insufficient detection comprehensiveness and accuracy.
[0005] Furthermore, traditional equipment suffers from insufficient safety protection and quality control, imperfect limit alarm mechanisms in transmission and welding modules, and limited detection dimensions, making it difficult to comprehensively identify weld defects. Consequently, it fails to meet the demands of modern production for efficiency, precision, flexibility, and safety. Therefore, integrated equipment is urgently needed to address these issues. Summary of the Invention
[0006] The purpose of this invention is to provide an integrated laser welding and weld inspection device and method, solving the problems of time-consuming transfer, low accuracy, poor equipment adaptability, insufficient automation, and inadequate safety and quality control caused by the separation of welding and inspection in existing technologies, as well as the problems of single function, low efficiency, and lagging inspection in traditional equipment. The device of this invention uses a main frame as a carrier, integrating core components such as laser welding, weld inspection, clamping devices, pressing devices, and push-out mechanisms. Multiple sets of slider guides and pneumatic and electric transmission devices enable flexible spatial adjustment of each module. The worktable is equipped with photoelectric sensors to accurately position welded parts of different specifications, and the clamping and pressing devices ensure reliable clamping. The integrated design is adaptable to various welding specifications and complex weld inspection scenarios, and the laser power, welding speed, and inspection accuracy can be adjusted as needed. Combined with the integrated control system and the automated intelligent design of 3D vision camera for all-dimensional inspection, it achieves efficient and accurate welding and inspection of various welded parts.
[0007] The above-mentioned objective of the present invention is achieved through the following technical solution:
[0008] An integrated laser welding and weld inspection device includes a laser welding unit, a weld inspection unit, a clamping unit, a clamping unit, a worktable, a main frame, and a pushing device. The worktable is mounted on the main frame, with a base plate serving as the conveying path for the workpiece. Several photoelectric sensors are installed to position the workpiece. The laser welding unit is mounted on the main frame, at the next station on the worktable, corresponding to the photoelectric sensors. A lens changing mechanism is installed below the laser welding unit, using a rotary cylinder module to rotate the laser lens and cooperate with the lens changing mechanism to replace the lens. The weld inspection unit is mounted on the main frame, at the next station on the laser welding unit, corresponding to the photoelectric sensors, and performs weld inspection at different locations. The clamping and clamping units are mounted on the main frame and correspond to the photoelectric sensors, with the clamping unit located above the clamping unit. The pushing device is mounted on the side of the clamping unit. A recovery slide and a waste slide are installed at different positions at the end of the worktable.
[0009] The laser welding device comprises: a laser lens mounted on a rotary cylinder module, and a laser mounted on a laser support plate; a support plate one mounted on a slider two, slider two mounted on a guide rail two, and guide rail two mounted on a main frame; guide rail one mounted on support plate one, and slider one mounted on guide rail one; a rodless cylinder mounted on support plate one, and a connecting plate connecting the laser support plate and the rodless cylinder to control the vertical movement of the laser; a ball screw module mounted on the main frame and connected to support plate one to control the lateral movement of the laser; a lens changing mechanism mounted below the rotary cylinder module, a rod cylinder one mounted on the main frame, a lens scraper mounted on rod cylinder one, a rod cylinder two mounted on the main frame, a pneumatic finger mounted on rod cylinder two, and a lens changer mounted on the pneumatic finger.
[0010] The laser lens contains an electromagnet, and the lens has a magnetic ring. When energized, the lens is attracted to the laser lens. The lens replacement mechanism has an electromagnet, and the lens replacement mechanism is magnetized or demagnetized by controlling the current, thereby completing the removal or transfer of the lens of the laser lens.
[0011] The weld inspection device comprises: cylinder one and guide rail three fixed on the main frame, slider three mounted on guide rail three, and support plate two mounted on slider three; guide rail four fixed on the main frame, inspection shell mounted on guide rail four, cylinder two mounted on support plate two and connected to the inspection shell; dual cylinder series control is adopted to achieve flexible stroke expansion, segmented controllable motion, and fine load adjustment; the inspection shell is equipped with a belt drive module, a longitudinal slider guide rail module, and a vertical slider guide rail module, the longitudinal slider guide rail module mounted on the vertical slider guide rail module, and a 3D vision camera mounted on the longitudinal slider guide rail module to realize left-right and up-down movement during inspection; a vision controller is mounted on the inspection shell.
[0012] The clamping device includes several rod cylinders, each mounted on the main frame. The number of rod cylinders is the same as the number of photoelectric sensors, and the center line of each rod cylinder corresponds to the center line of the photoelectric sensor, thereby ensuring positioning accuracy.
[0013] The clamping device consists of: a pneumatic gripper finger fixed on the lower crossbeam, a slide rail fixed on the upper crossbeam, and the upper crossbeam fixed to the main frame via a connecting block; a slider four is mounted on the slide rail and connected to the lower crossbeam, and the slider four cooperates with the slide rail to drive the pneumatic gripper finger to move, each movement corresponding to the center line of the photoelectric sensor, thereby cooperating with the pressing device to achieve the clamping and pressing functions.
[0014] The workbench is as follows: the base is fixed on the main frame, the profile is supported by multiple bases to form the main frame of the workbench, the electric pusher is installed on the profile, the working base plate is fixed on the profile, the stop block is fixed on the working base plate, and several photoelectric sensors are installed on one side of the profile, corresponding to the center positions of the electric pusher, the laser welding device and the weld detection device.
[0015] The main frame is composed of profile two, the base plate is fixed on profile two, and the recycling slide and waste slide are respectively installed at the end of the workbench; the central control unit is installed on the base plate.
[0016] The pushing device consists of: a support plate three installed on the side of the clamping device, a support frame installed on the support plate three, a cylinder three installed on the support frame, a guide rail five installed on the support plate three, a slider five installed on the guide rail five, and a push plate installed on the slider five; the pushing device selects whether to push the weldment into the scrap slide table based on the detection judgment of the weld detection device.
[0017] Another objective of this invention is to provide a detection method for a highly adaptable integrated laser welding and weld inspection device, comprising the following steps:
[0018] Step 1: Power on the central control unit and initialize the system data. Based on the material, size and welding inspection process requirements of the workpiece, set the working parameters of each device, including the laser power and welding speed of the laser welding device, the inspection accuracy and movement path of the weld inspection device, as well as the clamping force of the clamping device and the pressing device, and the moving speed of the horizontal slider guide module and the vertical slider guide module.
[0019] Step 2: After the parameters are set, the system starts the conveying control according to the preset workstation process. The electric pusher of the worktable pushes the workpiece to be welded to the pneumatic finger, and the central control unit adjusts the transmission speed in real time.
[0020] Step 3: The photoelectric sensor and the 3D vision camera of the weld seam detection device work together. The photoelectric sensor first performs preliminary positioning of the workpiece to be welded and transmits the position data to the central control unit.
[0021] Step 4: The central control unit distributes positioning data to the laser welding device, weld detection device, clamping device, and pressing device. The clamping device moves to the corresponding position through the cooperation of slider four and slide rail. The rod-type cylinder three of the clamping device moves down synchronously to achieve clamping and pressing coordination. At the same time, the ball screw module and rodless cylinder drive the laser welding device to move to the welding station. Cylinder one and cylinder two of the weld detection device and the horizontal and vertical slider guide rail modules drive the 3D vision camera to position. The lens changing mechanism completes the lens pre-switching according to the welding requirements.
[0022] Step 5: After the above steps are completed, the central control unit sends a linkage signal, the laser welding device starts welding, and the weld detection device is immediately triggered after welding to perform full-dimensional detection. The detection data is transmitted back in real time. Qualified welded parts are pushed to the recycling slide by the pusher device, and unqualified parts are pushed into the waste slide.
[0023] The beneficial effects of this invention are as follows: Structurally, it employs a high-strength worktable, a high-precision electric and pneumatic device, and multiple sets of slider guide rail transmission devices, achieving simple, reliable, and stable operation. It can flexibly switch the positions of the laser welding device, weld inspection device, clamping device, and locking device at different levels and heights, adapting to weldments of different shapes, sizes, and materials. In terms of automation, only manual material loading is required; the position of the weldment is accurately detected by photoelectric sensors, automatically completing the entire process of positioning, welding, and inspection, significantly simplifying operation and improving efficiency. For quality assurance, it integrates advanced laser vision inspection technology, which can accurately identify minute surface and internal defects in real time. Automated operation reduces the impact of human factors, ensuring consistent and stable welding quality. It effectively solves the problems of traditional equipment's single function, low efficiency, and delayed inspection, providing efficient and high-quality welding and inspection solutions for multiple industries. Attached Figure Description
[0024] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate the invention and are used to explain it, but do not constitute an undue limitation of the invention.
[0025] Figure 1 This is a three-dimensional structural diagram of the present invention;
[0026] Figure 2 This is a three-dimensional structural schematic diagram of the present invention from another angle;
[0027] Figure 3 This is a three-dimensional structural diagram of the laser welding device of the present invention;
[0028] Figure 4 for Figure 3 The diagram shows the structural diagram of the welding part of the laser welding device.
[0029] Figure 5 for Figure 3 A schematic diagram of the lens replacement mechanism of the laser welding device shown.
[0030] Figure 6 This is a three-dimensional structural diagram of the weld inspection device of the present invention;
[0031] Figure 7 for Figure 6 Front view structural diagram;
[0032] Figure 8This is a three-dimensional structural diagram of the clamping device of the present invention;
[0033] Figure 9 This is a three-dimensional structural diagram of the clamping device of the present invention;
[0034] Figure 10 This is a three-dimensional structural diagram of the worktable of the present invention;
[0035] Figure 11 This is a three-dimensional structural diagram of the pushing device of the present invention.
[0036] In the diagram: 1. Laser welding device; 2. Weld inspection device; 3. Clamping device; 4. Clamping device; 5. Worktable; 6. Main frame; 7. Pushing device; 11. Lens changing mechanism; 101. Rotary cylinder module; 102. Laser lens; 103. Laser; 104. Connecting plate; 105. Rodless cylinder; 106. Ball screw module; 107. Guide rail one; 108. Slider one; 109. Laser support plate; 110. Slider two; 111. Guide rail two; 112. Support plate one; 113. Rod cylinder one; 114. Lens scraper; 115. Lens changer; 116. Pneumatic finger; 117. Rod cylinder two; 201. Cylinder one; 202. Guide rail three; 203. Slider three; 204. Support plate two; 205. Guide rail four; 206. Inspection shell; 207. Cylinder II; 208. 3D Vision Camera; 209. Belt Drive Module; 210. Vertical Slider Guide Rail Module; 211. Longitudinal Slider Guide Rail Module; 212. Vision Controller; 301. Rod-Mounted Cylinder III; 401. Pneumatic Gripper Finger; 402. Lower Crossbeam; 403. Upper Crossbeam; 404. Slide Rail; 405. Slider IV; 406. Connecting Block; 501. Base; 502. Profile I; 503. Electric Pusher; 504. Working Base Plate; 505. Stop Block; 506. Photoelectric Sensor; 601. Base Plate; 602. Recycling Slide Table; 603. Waste Material Slide Table; 604. Central Control All-in-One Machine; 605. Profile II; 701. Support Plate III; 702. Cylinder III; 703. Support Frame; 704. Guide Rail V; 705. Slider V; 706. Push Plate. Detailed Implementation
[0037] The technical solutions in 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. To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.
[0038] See Figures 1 to 11 As shown, the integrated laser welding and weld inspection equipment and method of this invention offers a comprehensive upgrade in adaptability, covering multiple scenarios and specifications. The equipment's welding device is more flexible: precise horizontal and vertical movement of the laser is achieved through a ball screw module and rodless cylinders, coupled with a lens-changing mechanism based on electromagnets, allowing for rapid lens switching to adapt to weldments of different materials and thicknesses. Simultaneously, the equipment's clamping structure is more adaptable: the clamping device, through the cooperation of sliders and slide rails, drives the pneumatic clamping fingers to move, precisely aligning with the pressing device, adapting to weldments of different sizes and shapes. Furthermore, the welding process of this equipment is more complete, integrating welding, inspection, clamping, conveying, pushing, and sorting / recycling modules, achieving closed-loop automation from workpiece loading, positioning, welding, inspection to qualified / unqualified product sorting. In summary, compared to traditional laser welding equipment and existing inventions, this invention represents a comprehensive upgrade in technical design, functional implementation, and practical application value. Its adaptability achieves a breakthrough across scenarios, deeply integrates automation and intelligence, further improves safety and quality control, and its structural design combines practicality and scalability. This invention addresses the pain points of traditional welding inspection equipment, such as poor adaptability, insufficient automation, limited inspection accuracy, and lack of safety control, providing an efficient, accurate, and safe integrated solution for diverse production needs across multiple industries.
[0039] See Figure 1 and Figure 2 As shown, the integrated laser welding and weld inspection equipment of the present invention is based on the main frame 6 and integrates core components such as the laser welding device 1, weld inspection device 2, clamping device 3, clamping device 4, worktable 5, and pushing device 7. Its compact and reliable structure, combined with efficient collaboration, effectively improves production efficiency and operational accuracy, adapting to diverse production needs. It boasts outstanding safety and practicality, flexibly adapting to applications with high automation and complex operating conditions. The worktable 5 is equipped with photoelectric sensors 506 to achieve precise positioning of each station, and the clamping device 4 is precisely aligned with the clamping device 3 above for reliable clamping. The laser welding device 1 is driven by multiple modules such as the rotary cylinder module 101 and the ball screw module 106, and combined with the lens changing mechanism 11 based on the electromagnet principle, it achieves flexible lens adjustment and rapid lens replacement, ensuring welding adaptability. The weld inspection device 2 adopts dual-cylinder series control and horizontal and vertical slider guide modules, and is equipped with a 3D vision camera 208 to achieve multi-directional high-precision inspection. The pusher 7 can sort the welded parts to the recycling slide or waste slide according to the detection results. The laser welding device 1, weld detection device 2, clamping device 3, and clamping device 4 are all equipped with limit switches, alarms and position detection feedback systems. The whole process is fully automated from positioning, clamping, welding, lens changing, detection to sorting, with high precision, high adaptability and high safety.
[0040] The workbench 5 is mounted on the main frame 6, and the work surface 504 serves as the conveying path for the workpieces to be welded. A photoelectric sensor 506 is installed to position the workpieces. The laser welding device 1 is mounted on the main frame 6, at the next station of the workbench 5, corresponding to the photoelectric sensor 506. A lens changing mechanism 11 is installed below the laser welding device 1. A rotary cylinder module 101 can rotate the laser lens 102 to replace the lens with the lens changing mechanism 11. The weld detection device 2 is mounted on the main frame 6, at the next station of the laser welding device 1, corresponding to the photoelectric sensor 506. The weld detection device 2 has multiple built-in guide rails, sliders, and transmission belts to realize weld detection at different positions. The clamping device 4 and the pressing device 3 are mounted on the main frame 6 and correspond to the photoelectric sensor 506. The pressing device 3 is above the clamping device 4. The pushing device 7 is mounted on the side of the pressing device 3. The recycling slide 602 and the waste slide 603 are respectively installed at different positions at the end of the workbench 5.
[0041] See Figures 3 to 5 As shown, the laser welding device 1 includes a rotary cylinder module 101, a laser lens 102, a laser 103, a connecting plate 104, a rodless cylinder 105, a ball screw module 106, a guide rail 107, a slider 108, a laser support plate 109, a slider 110, a guide rail 111, a support plate 112, a rod cylinder 113, a lens scraper 114, a lens changer 115, a pneumatic finger 116, and a rod cylinder 117. The laser lens 102 is mounted on the rotary cylinder module 101; the laser 103 is mounted on the laser support plate 109; the support plate 112 is mounted on the slider 110, the slider 110 is mounted on the guide rail 111, and the guide rail 111 is mounted on the main frame 6; the guide rails... A 107 is mounted on a support plate 112, and a slider 108 is mounted on a guide rail 107. A rodless cylinder 105 is mounted on the support plate 112, and a connecting plate 104 connects the laser support plate 109 and the rodless cylinder 105 to control the vertical movement of the laser 103. A ball screw module 106 is mounted on the main frame 6 and connected to the support plate 112 to control the lateral movement of the laser. A lens changing mechanism 11 is mounted below the rotary cylinder module 101, a rod cylinder 113 is mounted on the main frame 6, a lens scraper 114 is mounted on the rod cylinder 113, a rod cylinder 117 is mounted on the main frame 6, a pneumatic finger 116 is mounted on the rod cylinder 117, and a lens changer 115 is mounted on the pneumatic finger 116.
[0042] The laser lens 102 contains an electromagnet, and the lens has a magnetic ring. When energized, the lens can be attracted to the laser lens 102. The lens replacement process relies on the electromagnet principle. The lens replacement mechanism 11 also has an electromagnet. By controlling the current, the lens replacement mechanism 11 is magnetized or demagnetized, thereby completing the removal or transfer of the lens of the laser lens 102.
[0043] The ball screw module 106 responds to the positioning signal of the workpiece to be welded, and drives the support plate 112 to move precisely longitudinally through the sliding cooperation of the slider 110 and the guide rail 111. The rodless cylinder 105 operates synchronously, and with the guidance of the guide rail 107 and the slider 108, drives the laser support plate 109 and the laser 103 mounted on it to be adjusted smoothly laterally. At the same time, the rotary cylinder module 101 drives the laser lens 102 to rotate and finely adjust according to the spatial angle requirements of the weld seam of the workpiece to be welded, so as to ensure that the laser lens 102 is accurately aligned with the area to be welded and to ensure welding accuracy.
[0044] When the welding process requires lens replacement, the rotary cylinder module 101 drives the laser lens 102 to rotate 90°, so that the laser lens 102 and the lens changer 115 are precisely aligned. Then, the rod cylinder 113 drives the lens scraper 114 to move, assisting in the peeling off of the old lens on the laser lens 102. Next, the pneumatic finger 116 holds the preset new lens and pushes it along the preset path to directly below the laser lens 102 under the drive of the rod cylinder 117. Utilizing the magnetic ring on the lens and the adsorption principle of the electromagnet built into the laser lens 102, the laser lens 102 is magnetically attracted to the new lens by controlling the current flow. At the same time, the lens changer 115 demagnetizes and releases the lens, completing the rapid lens replacement of the laser lens 102 and ensuring that the equipment is adaptable to the welding needs of workpieces of different materials and thicknesses.
[0045] See Figure 6 and Figure 7As shown, the weld inspection device 2 includes a cylinder 201, a guide rail 202, a slider 203, a support plate 204, a guide rail 205, an inspection shell 206, a cylinder 207, a 3D vision camera 208, a belt drive module 209, a longitudinal slider guide rail module 211, a vertical slider guide rail module 210, and a vision controller 212. The cylinder 201 is fixed on the main frame 6, the guide rail 202 is fixed on the main frame 6, the slider 203 is mounted on the guide rail 202, the support plate 204 is mounted on the slider 203, the guide rail 205 is fixed on the main frame 6, the inspection shell 206 is mounted on the guide rail 205, and the cylinder 207 is mounted on the support plate 204 and connected to the inspection shell 206. The device employs a dual-cylinder series control, enabling flexible stroke expansion, segmented controllable motion, and fine load adjustment, while also improving safety redundancy and adaptability to complex scenarios. The detection housing 206 contains a belt drive module 209, a longitudinal slider guide module 211, and a vertical slider guide module 210. The longitudinal slider guide module 211 is mounted on the vertical slider guide module 210. The 3D vision camera 208 is mounted on the longitudinal slider guide module 211. This layout enables left-right and up-down movement during detection. The vision controller 212 is mounted on the detection housing 206.
[0046] The cylinder 201 responds to the detection command of the central control unit 604 and drives the support plate 204 to be initially positioned laterally through the sliding guide cooperation of the guide rail 202 and the slider 203. The cylinder 207 moves in sync and, with the guidance of the guide rail 205, drives the detection shell 206 to be smoothly adjusted laterally. The precise positioning of the detection shell 206 in the lateral space is achieved through the series control of the two cylinders, ensuring that the 3D vision camera 208 accurately focuses on the weld position.
[0047] After the detection is started, the vision controller 212 sends an action signal, and the belt drive module 209 drives the longitudinal slider guide module 211 to move along the preset trajectory. At the same time, the longitudinal slider guide module 211 moves vertically under the support of the vertical slider guide module 210. The two work together to drive the 3D vision camera 208 to complete the full-dimensional scanning detection of the weld. During the detection process, the 3D vision camera 208 collects weld image data in real time and transmits it back to the vision controller 212. The vision controller 212 analyzes and processes the data, accurately identifies defects such as cracks and pores on the surface and inside of the weld, forms the detection results, and feeds them back to the central control unit, providing a basis for subsequent sorting of qualified / unqualified products.
[0048] See Figure 8As shown, the clamping device 3 includes several rod cylinders 301, which are respectively installed on the main frame 6. The number of rod cylinders 301 is the same as the number of photoelectric sensors 506, and the center line of each rod cylinder 301 corresponds to the center line of the photoelectric sensor 506, thereby ensuring positioning accuracy.
[0049] See Figure 9 As shown, the clamping device 4 includes a pneumatic gripping finger 401, a lower crossbeam 402, an upper crossbeam 403, a slide rail 404, a slider 405, and a connecting block 406. The pneumatic gripping finger 401 is fixed on the lower crossbeam 402, the slide rail 404 is fixed on the upper crossbeam 403, and the connecting block 406 connects the upper crossbeam 403 and the main frame 6. The slider 405 is mounted on the slide rail 404 and connected to the lower crossbeam 402. The slider 405 cooperates with the slide rail 404 to drive the pneumatic gripping finger 401 to move. Each movement corresponds to the center line of the photoelectric sensor 506, thereby cooperating with the pressing device 3 to achieve the clamping and pressing functions.
[0050] See Figure 10 As shown, the workbench 5 includes a base 501, a profile 502, an electric pusher 503, a working base plate 504, a stop block 505, and several photoelectric sensors 506. The base 501 is fixed on the main frame 6. The profile 502 is supported by multiple bases 501 to form the main frame of the workbench 5. The electric pusher 503 is installed on the profile 502. The working base plate 504 is fixed on the profile 502. The stop block 505 is fixed on the working base plate 504. Several photoelectric sensors 506 are installed on the side of the profile 502 and correspond to the center positions of the electric pusher 503, the laser welding device 1, and the weld detection device 2.
[0051] See Figure 2 As shown, the main frame 6 includes a base plate 601, a recycling slide 602, a waste slide 603, a central control unit 604, and a second profile 605; the second profile 605 constitutes the main frame of the equipment, the base plate 601 is fixed on the second profile 605, the recycling slide 602 and the waste slide 603 are respectively installed at different positions at the end of the workbench 5; the central control unit 604 is installed on the base plate 601.
[0052] See Figure 11As shown, the pushing device 7 includes a support plate 701, a cylinder 702, a support frame 703, a guide rail 704, a slider 705, and a push plate 706. The support plate 701 is installed on the side of the clamping device 3, the support frame 703 is installed on the support plate 701, the cylinder 702 is installed on the support frame 703, the guide rail 704 is installed on the support plate 701, the slider 705 is installed on the guide rail 704, and the push plate 706 is installed on the slider 705. The pushing device 7 can select whether to push the sheet metal part into the scrap slide table 603 according to the detection judgment of the weld detection device 2.
[0053] The laser welding device 1, weld detection device 2, clamping device 3, clamping device 4, and pushing device 7, especially the ball screw module and guide rail slider module with transmission function, are all equipped with limit switches and alarms. At the same time, this equipment has a strict photoelectric sensor detection and a feedback system dominated by the central control integrated machine to ensure the accuracy and safety of welding.
[0054] See Figures 1 to 11 As shown, the working process of this invention is as follows:
[0055] The working process of the equipment of this invention is orderly flowed according to the work station, and the whole process realizes automated collaborative operation: First, the worker places the workpiece to be welded at the initial loading position of the workbench 5. The electric pusher 503 pushes the workpiece to be welded along the conveying path of the workbench and pushes the workpiece to the pneumatic finger 116. The photoelectric sensor 506 installed on the side of the workbench 5 immediately detects the position of the workpiece to be welded and feeds back a signal. At this time, the pneumatic clamping finger 401 of the clamping device 4 moves to the corresponding position under the cooperation of the slide rail 404 and the slider 405, and is precisely aligned with the rod cylinder 301 of the upper pressing device 3 (the center line is aligned with the photoelectric sensor 506), and together completes the clamping and fixing of the workpiece to be welded. Subsequently, the clamping device 4 drives the workpiece to be welded to be precisely transferred to the next laser welding device 1 via the slider 405 and the slide rail 404. At this time, the laser welding device 1 is activated according to the positioning signal of the photoelectric sensor 506. The ball screw module 106 and the rodless cylinder 105 drive the laser 103 to complete the horizontal and vertical position adjustment. The rotating cylinder module 101 drives the laser lens 102 to align with the weld. If the lens needs to be replaced, it is replaced by the electromagnet adsorption principle of the lens replacement mechanism 11, thereby achieving precise welding. After welding is completed, the welded parts are transferred to the weld inspection device 2 under the action of the clamping device 4. The double cylinders of the weld inspection device 2 drive the inspection shell 206 to move, and the internal horizontal and vertical slider guide rail module drives the 3D vision camera 208 to perform all-round inspection of the weld. After the inspection is completed, the welded parts are transferred to the end of the worktable 5. The pushing device 7 acts according to the inspection results - the cylinder 3 702 drives the push plate 706 to slide along the guide rail 5 704, and cooperates with the horizontal movement of the clamping device 4 to push the qualified welded parts into the recycling slide 602, while the unqualified welded parts are pushed into the waste slide 603, completing the entire welding inspection and sorting recycling process.
[0056] See Figures 1 to 11 As shown, the detection method of the highly adaptable integrated laser welding and weld inspection equipment of the present invention includes the following steps:
[0057] Step 1: Power on the central control unit 604, initialize system data, and set the working parameters of each device according to the material, size and welding inspection process requirements of the weldment, including the laser power and welding speed of the laser welding device 1, the detection accuracy and movement path of the weld inspection device 2, as well as the clamping force of the clamping device 4 and the pressing device 3, and the moving speed of the horizontal slider guide module and the vertical slider guide module, etc.
[0058] Step 2: After the parameters are set, the system starts the transmission control according to the preset workstation process. The electric pusher 503 of the worktable 5 pushes the workpiece to be welded to the pneumatic finger. The central control unit 604 adjusts the transmission speed in real time to ensure that it matches the rhythm of the laser welding device 1, weld detection device 2, pressing device 3, clamping device 4, and pushing device 7.
[0059] Step 3: The photoelectric sensor 506 and the 3D vision camera 208 of the weld seam detection device 2 work together. The photoelectric sensor 506 first performs preliminary positioning of the workpiece to be welded and transmits the position data to the central control unit 604.
[0060] Step 4: The central control unit 604 distributes positioning data to the clamping device 3 and the clamping device 4. The clamping device 4 moves to the corresponding position through the cooperation of the slider 405 and the slide rail 404. The rod cylinder 301 of the clamping device 3 moves down synchronously to achieve clamping and pressing coordination. At the same time, the ball screw module 106 and the rodless cylinder 105 drive the laser welding device 1 to move to the welding station. The double cylinder of the weld detection device 2 and the horizontal slider guide rail module and the vertical slider guide rail module drive the 3D vision camera 208 to position. The lens changing mechanism 11 completes the lens pre-switching according to the welding requirements.
[0061] Step 5: After the above steps are completed, the central control unit 604 sends a linkage signal, the laser welding device 1 starts welding, and the weld detection device 2 is immediately triggered to perform full-dimensional detection after welding is completed. The detection data is transmitted back in real time. Qualified welded parts are pushed to the recycling slide table 602 by the pusher device 7, and unqualified parts are pushed into the waste slide table 603.
[0062] Step 6: The photoelectric sensor 506 detects whether there is a new weldment at the initial feeding position. If so, the laser welding device 1, weld detection device 2, clamping device 3, clamping device 4, and pushing device 7 return to their positions, and the above process is repeated; otherwise, the system enters standby mode.
[0063] Step 7: Abnormal Handling: The limit switches and position detection systems of laser welding device 1, weld seam detection device 2, clamping device 3, clamping device 4, and pushing device 7 monitor the operating status in real time. If abnormalities such as welding deviation, clamping failure, or movement jamming occur, the central control unit 604 will immediately trigger an emergency stop, the alarm device will start and display the fault location to ensure operational safety.
[0064] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made to the present invention should be included within the scope of protection of the present invention.
Claims
1. An integrated laser welding and weld inspection device, characterized in that: The system includes a laser welding device (1), a weld inspection device (2), a clamping device (3), a clamping device (4), a worktable (5), a main frame (6), and a pushing device (7). The worktable (5) is installed on the main frame (6), and the table surface composed of the working base plate (504) serves as the conveying path for the workpiece. Several photoelectric sensors (506) are installed to position the workpiece. The laser welding device (1) is installed on the main frame (6) at the next station of the worktable (5), corresponding to the photoelectric sensors (506). A lens changing mechanism (11) is installed below the laser welding device (1) to rotate the laser mirror through a rotary cylinder module (101). The head (102) works in conjunction with the lens replacement mechanism (11) to replace the lens; the weld detection device (2) is installed on the main frame (6), at the next station of the laser welding device (1), corresponding to the photoelectric sensor (506), and the weld detection device (2) realizes weld detection at different positions; the clamping device (4) and the pressing device (3) are installed on the main frame (6) and correspond to the photoelectric sensor (506), and the pressing device (3) is located above the clamping device (4); the pushing device (7) is installed on the side of the pressing device (3); the recycling slide (602) and the waste slide (603) are respectively installed at different positions at the end of the worktable (5); The clamping device (3) includes several rod cylinders (301), which are installed on the main frame (6). The number of rod cylinders (301) installed is the same as the number of photoelectric sensors (506), and the center line of each rod cylinder (301) corresponds to the center line of the photoelectric sensor (506), thereby ensuring positioning accuracy. The clamping device (4) consists of: a pneumatic gripper finger (401) fixed on the lower crossbeam (402), a slide rail (404) fixed on the upper crossbeam (403), and the upper crossbeam (403) fixed to the main frame (6) via a connecting block (406); a slider four (405) mounted on the slide rail (404) and connected to the lower crossbeam (402), the slider four (405) and the slide rail (404) working together to drive the pneumatic gripper finger (401) to move, each movement aligning with the center of the photoelectric sensor (506). The lines correspond to each other, thus cooperating with the clamping device (3) to achieve clamping and pressing functions; the clamping device (4) moves to the corresponding position through the cooperation of the slider four (405) and the slide rail (404), and the rod cylinder three (301) of the pressing device (3) moves down synchronously to achieve clamping and pressing coordination; after welding is completed, the weld detection device (2) is immediately triggered to perform full-dimensional detection, and the detection data is transmitted back in real time; qualified welds are pushed to the recycling slide (602) by the pusher device (7), and unqualified welds are pushed into the waste slide (603).
2. The integrated laser welding and weld inspection equipment according to claim 1, characterized in that: The laser welding device (1) is as follows: a laser lens (102) is mounted on a rotary cylinder module (101), and a laser (103) is mounted on a laser support plate (109); a support plate (112) is mounted on a slider (110), the slider (110) is mounted on a guide rail (111), and the guide rail (111) is mounted on the main frame (6); a guide rail (107) is mounted on a support plate (112), and a slider (108) is mounted on a guide rail (107); a rodless cylinder (105) is mounted on a support plate (112), and a connecting plate (104) connects the laser support plate (109) and the rodless cylinder. The cylinder (105) controls the vertical movement of the laser (103); the ball screw module (106) is installed on the main frame (6) and connected to the support plate (112) to control the horizontal movement of the laser (103); the lens changing mechanism (11) is installed below the rotary cylinder module (101), the rod cylinder (113) is installed on the main frame (6), the lens scraper (114) is installed on the rod cylinder (113), the rod cylinder (2) is installed on the main frame (6), the pneumatic finger (116) is installed on the rod cylinder (2) (117), and the lens changer (115) is installed on the pneumatic finger (116).
3. The integrated laser welding and weld inspection equipment according to claim 2, characterized in that: The laser lens (102) contains an electromagnet and the lens has a magnetic ring. When energized, the lens is attracted to the laser lens (102). The lens exchange mechanism (11) has an electromagnet. By controlling the current, the lens exchange mechanism (11) is magnetized or demagnetized, thereby completing the picking or transferring of the lens of the laser lens (102).
4. The integrated laser welding and weld inspection equipment according to claim 3, characterized in that: The weld inspection device (2) is as follows: cylinder one (201) and guide rail three (202) are fixed on the main frame (6), slider three (203) is installed on guide rail three (202), and support plate two (204) is installed on slider three (203); guide rail four (205) is fixed on the main frame (6), inspection shell (206) is installed on guide rail four (205), cylinder two (207) is installed on support plate two (204) and connected to inspection shell (206); a dual-cylinder series control is adopted, which is effective. The current travel is flexible and expandable, the motion is segmented and controllable, and the load is finely adjusted; the detection housing (206) is equipped with a belt drive module (209), a longitudinal slider guide module (210) and a vertical slider guide module (211). The longitudinal slider guide module (210) is installed on the vertical slider guide module (211), and the 3D vision camera (208) is installed on the longitudinal slider guide module (210) to realize the left and right and up and down movement during detection; the vision controller (212) is installed on the detection housing (206).
5. The integrated laser welding and weld inspection equipment according to claim 1, characterized in that: The workbench (5) is as follows: the base (501) is fixed on the main frame (6), the profile (502) is supported by multiple bases (501) to form the main frame of the workbench (5), the electric pusher (503) is installed on the profile (502), the working base plate (504) is fixed on the profile (502), the stop block (505) is fixed on the working base plate (504), and several photoelectric sensors (506) are installed on the side of the profile (502) and correspond to the center position of the electric pusher (503), the laser welding device (1) and the weld detection device (2).
6. The integrated laser welding and weld inspection equipment according to claim 1, characterized in that: The main frame (6) is composed of profile two (605), the base plate (601) is fixed on profile two (605), the recycling slide (602) and the waste slide (603) are respectively installed at the end of the workbench (5); the central control unit (604) is installed on the base plate (601).
7. The integrated laser welding and weld inspection equipment according to claim 1, characterized in that: The pushing device (7) is as follows: support plate three (701) is installed on the side of the clamping device (3), support frame (703) is installed on support plate three (701), cylinder three (702) is installed on support frame (703), guide rail five (704) is installed on support plate three (701), slider five (705) is installed on guide rail five (704), and push plate (706) is installed on slider five (705); the pushing device (7) selects whether to push the welded part into the scrap slide table (603) according to the detection judgment of the weld detection device (2).
8. A laser welding and weld inspection method using the integrated laser welding and weld inspection equipment as described in claim 4, characterized in that: Includes the following steps: Step 1: The central control unit (604) is turned on and the system data is initialized. According to the material, size and welding inspection process requirements of the welded parts, the working parameters of each device are set, including the laser power and welding speed of the laser welding device (1), the detection accuracy and movement path of the weld detection device (2), and the clamping force of the clamping device (4) and the pressing device (3), as well as the moving speed of the vertical slider guide module and the longitudinal slider guide module. Step 2: After the parameters are set, the system starts the transmission control according to the preset workstation process. The electric pusher (503) of the workbench (5) pushes the workpiece to be welded to the pneumatic finger (116), and the central control unit (604) adjusts the transmission speed in real time. Step 3: The photoelectric sensor (506) and the 3D vision camera (208) of the weld detection device (2) work together. The photoelectric sensor (506) first performs preliminary positioning of the welded part and transmits the position data to the central control unit (604). Step 4: The central control unit (604) distributes positioning data to the laser welding device (1), weld detection device (2), pressing device (3) and clamping device (4). The clamping device (4) moves to the corresponding position through the cooperation of slider four (405) and slide rail (404). The rod cylinder three (301) of the pressing device (3) moves down synchronously to achieve clamping and pressing coordination. At the same time, the ball screw module (106) and rodless cylinder (105) drive the laser welding device (1) to move to the welding station. The cylinder one (201) and cylinder two (207) of the weld detection device (2) and the vertical slider guide rail module and longitudinal slider guide rail module drive the 3D vision camera (208) to position. The lens replacement mechanism (11) completes the lens pre-switching according to the welding requirements. Step 5: After the above steps are completed, the central control unit (604) sends a linkage signal, the laser welding device (1) starts welding, and the weld detection device (2) is triggered immediately after welding to perform full-dimensional detection. The detection data is transmitted back in real time. Qualified welded parts are pushed to the recycling slide (602) by the pusher device (7), and unqualified parts are pushed into the waste slide (603).