Automatic welding device for steel structure machining

Abstract

The invention discloses an automatic welding device for steel structure machining, and relates to the technical field of steel structure welding equipment. In order to solve the problems that existing equipment is only suitable for regular workpieces, the actual benchmark and the welding seam position are difficult to recognize, the clamping stability is poor, and welding deviation is likely to be caused, the device is composed of a main body rack, an X-axis arm, a Y-axis arm, a Z-axis arm, a welding gun assembly, a workpiece benchmark recognizing and reconstructing module, a welding seam recognizing device, a processor, a driving box body and a clamping and positioning assembly. Welding is completed by recognizing the actual reference of a workpiece and welding seam information and controlling the welding head to move in the multi-axis direction, meanwhile, the workpiece is stably positioned through the sliding clamping block, the guide rod, the elastic reset piece and the limiting block, and therefore the welding precision, the welding seam forming consistency and the adaptability to different steel structural components are improved.

Description

Technical Field

[0001] This invention relates to the field of steel structure welding equipment technology, specifically to an automated welding device for steel structure processing. Background Technology

[0002] Steel structure components are widely used in factories, bridges, prefabricated buildings, equipment supports, and large metal frames. In the steel structure fabrication process, welding is a crucial step in component forming and connection. With the increasing scale and standardization of steel structure fabrication, traditional manual or semi-automatic welding methods are gradually shifting towards automated welding equipment. Current technologies are beginning to employ gantry welding mechanisms, guide rail moving mechanisms, and identification and positioning devices to weld workpieces, thereby improving welding efficiency and consistency.

[0003] In actual use, existing automated steel structure welding equipment can only operate on workpieces with high regularity and fixed placement. When there are deviations in the size of the steel structure workpiece, the placement position is offset, or the weld seam to be welded is inconsistent with the preset trajectory, traditional equipment often still drives the welding torch to move according to the preset program. It lacks the ability to effectively identify and reconstruct the actual reference position of the workpiece and the actual position of the weld seam, which makes it easy for alignment errors to occur between the welding torch and the weld seam, thereby affecting the welding accuracy and weld formation quality.

[0004] In addition, conventional clamping mechanisms are poorly adapted to steel structural components of different widths and cross-sectional shapes, which may result in unstable clamping, inaccurate guidance, or local movement of the workpiece, making it difficult to maintain a stable position of the workpiece during welding. At the same time, the welding execution end of some equipment can only achieve simple unidirectional movement or fixed path movement, which limits its adaptability to multi-position welding and welding parts of different heights. Summary of the Invention

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an automated welding device for steel structure processing, wherein an X-axis arm is horizontally fixedly connected to the upper part of the main frame, an X-axis guide rail is fixedly connected to the front side of the X-axis arm, a Z-axis arm is slidably connected to the X-axis guide rail, a drive housing is fixedly connected to one end of the X-axis arm, the drive housing is drivenly connected to the Z-axis arm, a Z-axis guide rail is fixedly connected to the front side of the Z-axis arm, a welding torch assembly is slidably connected to the Z-axis guide rail, a welding head is fixedly connected to the lower end of the welding torch assembly, a workpiece reference recognition and reconstruction module and a weld seam recognition device are fixedly connected to the upper part of the Z-axis arm, a processor is fixedly connected to one side of the main frame, the workpiece reference recognition and reconstruction module and the weld seam recognition device are both electrically connected to the processor, and the processor is electrically connected to the drive housing and the welding torch assembly; Y-axis arms are fixedly connected to the lower left and right sides of the main frame, respectively. A Y-axis guide rail is fixedly connected to the upper side of the Y-axis arm. A transverse guide rail and a guide rod are fixedly connected to the inner side of the Y-axis arm. A sliding clamping block is slidably connected to the transverse guide rail. The sliding clamping block and the guide rod are slidably engaged. An elastic reset member is sleeved on the outer side of the guide rod. A limit block is fixedly connected to the Y-axis arm at a position outside the sliding clamping block. The elastic reset member is located between the sliding clamping block and the limit block.

[0006] Furthermore, the main frame includes two supporting bodies spaced apart on the left and right and a transverse connecting part connected between the upper ends of the two supporting bodies. The X-axis arm is fixedly connected to the front side of the transverse connecting part, and the two Y-axis arms are respectively fixedly connected to the opposite inner sides of the lower part of the two supporting bodies. The X-axis arm and the transverse connecting part, and the Y-axis arm and the supporting body are fixedly connected by connecting plates and bolts. The connecting plates are provided with mounting holes, and the diameter of the mounting holes is 0.2-0.5mm larger than the nominal diameter of the corresponding bolts.

[0007] Furthermore, the X-axis guide rail includes two linear guide rails arranged parallel to each other along the length of the X-axis arm. The two linear guide rails are fixedly connected to the front side of the X-axis arm by countersunk screws. A mounting plate is fixedly connected to the rear side of the Z-axis arm. The mounting plate is slidably engaged with the two linear guide rails by four sets of sliders. An X-axis lead screw parallel to the X-axis guide rail is provided in the drive housing. One end of the X-axis lead screw is connected to the output shaft of the drive motor through a coupling, and the other end is rotatably connected to the end of the X-axis arm through a bearing seat. The Z-axis arm is fixedly connected to a nut seat provided on the X-axis lead screw.

[0008] Furthermore, the workpiece reference recognition and reconstruction module is fixedly connected to the first mounting bracket on the upper front side of the Z-axis arm, and the weld recognition device is fixedly connected to the second mounting bracket on the upper side of the Z-axis arm. Both the first and second mounting brackets are detachably connected to the Z-axis arm by bolts. The detection end of the workpiece reference recognition and reconstruction module and the detection end of the weld recognition device are both set towards the area below the welding head, and the center line of the workpiece reference recognition and reconstruction module and the center line of the weld recognition device intersect below the axis of the welding head.

[0009] Furthermore, the sliding clamping block is configured as two, and the two sliding clamping blocks are respectively disposed on the two Y-axis arms and arranged opposite to each other. The two limiting blocks are respectively fixedly connected to the side of the two Y-axis arms away from the middle of the main frame, and each limiting block is fixedly connected to the corresponding Y-axis arm by bolts passing through elongated holes.

[0010] Furthermore, the elastic reset member is a compression spring, which is coaxially sleeved on the outside of the guide rod. The sliding clamping block has a first spring positioning hole on the side facing the limiting block, and the limiting block has a second spring positioning hole on the side facing the sliding clamping block. The two ends of the elastic reset member are respectively embedded in the first spring positioning hole and the second spring positioning hole.

[0011] Compared with the prior art, the present invention has the following beneficial effects: This invention, by incorporating a workpiece reference recognition and reconstruction module, a weld seam recognition device, a processor, and a welding execution structure consisting of an X-axis arm, a Z-axis arm, and a welding torch assembly on the main frame, enables the equipment to first identify the actual reference position of the workpiece and the position of the weld seam to be welded after the workpiece enters the welding area. Based on the identification results, it generates corresponding welding coordinate information and then controls the welding head to move to the corresponding welding position to perform welding. Compared to traditional equipment that directly operates according to a preset trajectory, this invention can adjust the welding path based on the actual placement of the workpiece, thereby reducing the alignment deviation between the welding torch and the weld seam, improving the accuracy of the welding position and the consistency of weld formation. It is particularly suitable for automated welding operations of steel structure components under conditions of dimensional errors and placement offsets.

[0012] This invention further enhances the stability of the workpiece before welding by incorporating a Y-axis arm, transverse guide rail, guide rod, sliding clamping block, limiting block, and elastic reset component at the lower part of the main frame. This reduces workpiece swaying, movement, and positioning instability during the welding process. Simultaneously, the welding execution end is adjustable in both the X and Z axes, adapting to the processing needs of steel structure components with varying widths, heights, and welding locations. Therefore, this invention not only improves the positioning and clamping methods for steel structure components during welding but also expands the applicability of the equipment to various workpieces and welding scenarios, thereby enhancing the automation level and continuous operation capability of steel structure processing. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is an enlarged view of part A of the present invention; Figure 3 This is an enlarged view of part B of the present invention; Figure 4 This is a block diagram of the control system and signal flow of the present invention.

[0014] In the diagram: 1. Main frame; 2. Sliding clamping block; 3. Limiting block; 4. Y-axis arm; 401. Y-axis guide rail; 5. X-axis arm; 6. Z-axis arm; 7. Welding head; 8. Welding torch assembly; 801. Workpiece reference recognition and reconstruction module; 802. Z-axis guide rail; 803. Weld seam recognition device; 9. Processor; 10. Drive housing; 11. Transverse guide rail; 12. Elastic reset component; 13. Guide rod; 14. X-axis guide rail. Detailed Implementation

[0015] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed merely to enable those skilled in the art to better understand and implement the subject matter described herein, and are not intended to limit the scope, applicability, or examples set forth in the claims. The function and arrangement of the elements discussed may be changed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the various examples. For example, the described methods may be performed in a different order than described, and steps may be added, omitted, or combined. Furthermore, features described in some examples may be combined in other examples.

[0016] As used herein, the term "comprising" and its variations are open terms meaning "including but not limited to". The term "based on" means "at least partially based on". The terms "one embodiment" and "an embodiment" mean "at least one embodiment". The term "another embodiment" means "at least one other embodiment". The terms "first", "second", etc., may refer to different or the same objects. Other definitions, whether explicit or implicit, may be included below. Unless explicitly indicated by the context, the definition of a term shall remain consistent throughout the specification.

[0017] Example Please see Figure 1-3 The present invention provides a technical solution: An automated welding device for steel structure processing includes an X-axis arm 5 horizontally fixedly connected to the upper part of the main frame 1, an X-axis guide rail 14 fixedly connected to the front side of the X-axis arm 5, a Z-axis arm 6 slidably connected to the X-axis guide rail 14, a drive housing 10 fixedly connected to one end of the X-axis arm 5, the drive housing 10 being drivenly connected to the Z-axis arm 6, a Z-axis guide rail 802 fixedly connected to the front side of the Z-axis arm 6, a welding torch assembly 8 slidably connected to the Z-axis guide rail 802, a welding head 7 fixedly connected to the lower end of the welding torch assembly 8, a workpiece reference recognition and reconstruction module 801 and a weld seam recognition device 803 fixedly connected to the upper part of the Z-axis arm 6, a processor 9 fixedly connected to one side of the main frame 1, the workpiece reference recognition and reconstruction module 801 and the weld seam recognition device 803 being electrically connected to the processor 9, and the processor 9 being electrically connected to the drive housing 10 and the welding torch assembly 8. Y-axis arms 4 are fixedly connected to the lower left and right sides of the main frame 1, respectively. Y-axis guide rail 401 is fixedly connected to the upper side of the Y-axis arm 4. A transverse guide rail 11 and a guide rod 13 are fixedly connected to the inner side of the Y-axis arm 4. A sliding clamping block 2 is slidably connected to the transverse guide rail 11. The sliding clamping block 2 and the guide rod 13 are slidably engaged. An elastic reset member 12 is sleeved on the outer side of the guide rod 13. A limit block 3 is fixedly connected to the Y-axis arm 4 at a position outside the sliding clamping block 2. The elastic reset member 12 is located between the sliding clamping block 2 and the limit block 3.

[0018] This device includes a main frame and various functional components mounted on it. The frame consists of two columns and a crossbeam. The X-axis arm is fixedly connected to the front of the crossbeam, and double rows of X-axis guide rails are arranged parallel to each other along the length of the X-axis arm, forming a linear guide rail in the X direction. The drive housing is fixed inside one end of the X-axis arm and houses the X-axis drive motor and ball screw to achieve X-axis drive. The drive housing is bolted to the flange at the end of the arm, with the connection hole diameter 0.2–0.5 mm larger than the bolt diameter for adjustment. The nut seat is mounted on the ball screw inside the drive housing and rigidly connected to the Z-axis arm. Therefore, when the motor rotates, it drives the Z-axis arm to move along the X-axis guide rail through the drive housing. The threaded nut on the X-axis guide rail is connected to the mounting plate on the rear side of the Z-axis arm. The mounting plate slides with the guide rail via a rolling slider, and the connection is secured with an elongated hole and a spring washer to ensure positioning accuracy and compensate for manufacturing deviations.

[0019] Two parallel Z-axis guide rails and a parallel ball screw are fixedly arranged on the front side of the Z-axis arm. The rear end of the welding torch assembly is fixed to a lifting mounting plate, which slides along the Z-axis guide rails via a built-in rolling slider and is connected to the Z-axis ball screw nut seat for Z-axis lifting adjustment. The welding head is threaded to the lower end of the welding torch assembly and is removable and replaceable. A workpiece reference recognition and reconstruction module is welded to the front of the upper part of the Z-axis arm, and a weld seam recognition device is fixed to the side; both are connected to a dedicated mounting plate with M6 screws. The optical or laser detection ends of the module and device face the welding area below the welding head to collect reference point or weld seam geometry information; for example, a structured light projector or laser contour sensor is used in conjunction with an industrial camera for image acquisition.

[0020] Y-axis arms are fixed to the left and right sides of the lower part of the frame, and the two arms are arranged in parallel. A horizontal guide rail and a guide rod are arranged on the upper side of each Y-axis arm, and the guide rail and guide rod are fixed to the arm body parallel to the arm width direction. A sliding clamping block is fitted onto the horizontal guide rail, with a linear slider at the bottom that mates with the guide rail. A through hole is opened on the side to mate with the guide rod, allowing the sliding clamping block to slide on the guide rod. The guide rod passes through the clamping block hole and is fixed to the Y-axis arm. An elastic reset component is fitted on its outer side; one end of the spring is fixed inside the clamping block, and the other end is fixed to a limiting block located outside the block. The spring provides preload to the clamping block. The limiting block limits the travel range of the clamping block to prevent over-clamping. The two clamping blocks are respectively installed on the two Y-axis arms, arranged opposite each other towards the center of the frame, to clamp the horizontally placed steel structure workpiece at two points.

[0021] In terms of the control system, an industrial control computer and PLC serve as the main control unit. The controller is electrically connected to the workpiece reference recognition module and weld seam recognition device via cables to receive the acquired image / point cloud data. The controller is also connected to the drive housing, Z-axis lead screw driver, solenoid valve, and welding power supply, outputting motion control signals. A cable chain organizes and leads out the sensor cables and power lines to ensure safe cable movement.

[0022] In operation, the operator places the steel structural component to be welded on the transverse guide rail between the two Y-axis arms and starts the conveying mechanism to push the workpiece into the clamping area. Once the workpiece touches the limit post or photoelectric switch at the front of the device, the controller receives a signal and issues a stop command, bringing the workpiece to a standstill in the predetermined position. Subsequently, the processor controls the hydraulic cylinder to push the two sliding clamping blocks inward, clamping the two edges of the workpiece. During clamping, the springs compress and release their elasticity, causing the clamping blocks to automatically conform to the workpiece surface and be finally positioned by the limit blocks. At this point, the workpiece has completed its transverse and longitudinal pre-positioning.

[0023] Next, weld seam datum recognition begins. The controller first activates the workpiece datum recognition module to scan the workpiece surface features; a structured light projector projects an coded grating pattern, an industrial camera captures the image, and the three-dimensional morphology of the workpiece surface is calculated using the phase measurement contour method. By transforming the camera and frame coordinate systems, the position information of the workpiece relative to the actual coordinate system of the frame can be obtained. Immediately afterwards, the weld seam recognition device scans the area of ​​the workpiece to be welded, using laser line scanning or a high-resolution camera to analyze the weld seam shape. The controller processes the datum information and weld seam image in parallel, extracting the two-dimensional coordinates of the weld seam and calculating its three-dimensional coordinates in the actual coordinate system using the aforementioned three-dimensional model. This step can refer to the phase shift encoding method to obtain the center trajectory and interpolate to obtain the curve trajectory. Finally, the processor generates the welding path coordinates and sends them to the downstream actuator.

[0024] The controller plans drive commands based on the generated coordinates. First, the controller drives the X-axis motor to rotate, causing the Z-axis arm to move along the crossbeam to the weld start position. The drive housing output torque drives the Z-axis arm through a ball screw, with its stroke and accuracy conforming to GB / T17587 or JB / T9003 standards. For example, a φ20mm ball screw with a 10mm lead can achieve a maximum linear speed of 0.4m / s at 2400rpm, with an axial clearance of less than 20μm, meeting the requirements for high-speed and high-precision motion. After reaching the start position, the welding power supply is activated, and the welding torch assembly begins welding. Weld seam tracking is a critical step: during welding, the weld seam recognition device continuously acquires images of the area in front of the weld seam and extracts the current weld seam centerline in real time through image processing algorithms. The controller performs closed-loop correction of the X-axis arm and Z-axis arm based on the weld seam position feedback, ensuring that the welding torch continuously tracks and moves along the weld seam center. The path can be split according to a set speed to control the synchronous movement of each axis. Typical X and Z motion speeds can be set to 0.1–0.3m / s, and the welding torch maintains a constant wire feed speed and compensates for angles. The welding torch posture can also be finely adjusted via a universal joint or additional joint to accommodate the weld bevel angle. The entire welding process control cycle can be set to 5–20 ms, with an image sampling frequency of approximately 50–100 Hz to respond in real time to weld changes.

[0025] After welding is completed, slag removal and quality inspection steps can be optionally activated. Slag generated by weld spatter can be removed using a roller brush or air blower. Subsequently, if a 2D / 3D profile sensor is integrated for visual inspection of the weld, 3D data of the weld profile can be acquired. This profile sensor has a Z-axis resolution of over 2μm and can detect welding defects such as dents, cracks, and over-protrusions. If the detection results exceed the preset tolerance, the control system can issue an alarm or a re-welding command. Afterward, the workpiece can be pushed out via a transverse guide rail, or removed manually / by a robotic arm, completing one welding cycle.

[0026] Those skilled in the art will understand that the various embodiments disclosed above can be modified and altered in various ways without departing from the spirit of the invention. Therefore, the scope of protection of this invention should be defined by the appended claims.

[0027] It should be noted that not all steps and units in the above processes are necessary; some steps or units can be omitted as needed. The execution order of each step is not fixed and can be determined as required. The device structure described in the above embodiments can be a physical structure or a logical structure. That is, some units may be implemented by the same physical entity, or some units may be implemented by multiple physical entities, or they may be jointly implemented by certain components in multiple independent devices.

[0028] The specific embodiments described above are exemplary embodiments, but do not represent all embodiments that can be implemented or fall within the scope of the claims. The term "exemplary" as used throughout this specification means "serving as an example, instance, or illustration" and does not imply that it is "preferred" or "advantageous" compared to other embodiments. Specific details are included to provide an understanding of the described techniques. However, these techniques can be practiced without these specific details. In some instances, well-known structures and apparatuses are shown in block diagram form to avoid obscuring the concepts of the described embodiments.

[0029] The foregoing description of this disclosure is provided to enable any person skilled in the art to implement or use this disclosure. Various modifications to this disclosure will be apparent to those skilled in the art, and the general principles defined herein can be applied to other variations without departing from the scope of this disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but is consistent with the widest scope of the principles and novel features disclosed herein.

Claims

1. An automated welding device for steel structure processing, comprising a main frame (1), a welding torch assembly (8), and a drive housing (10), characterized in that: An X-axis arm (5) is horizontally fixedly connected to the upper part of the main frame (1). An X-axis guide rail (14) is fixedly connected to the front side of the X-axis arm (5). A Z-axis arm (6) is slidably connected to the X-axis guide rail (14). A drive housing (10) is fixedly connected to one end of the X-axis arm (5). The drive housing (10) is drivenly connected to the Z-axis arm (6). A Z-axis guide rail (802) is fixedly connected to the front side of the Z-axis arm (6). A welding torch assembly is slidably connected to the Z-axis guide rail (802). The welding gun assembly (8) is fixedly connected to a welding head (7) at its lower end. The Z-axis arm (6) is fixedly connected to a workpiece reference recognition and reconstruction module (801) and a weld seam recognition device (803) at its upper part. The main frame (1) is fixedly connected to a processor (9) on one side. The workpiece reference recognition and reconstruction module (801) and the weld seam recognition device (803) are both electrically connected to the processor (9). The processor (9) is electrically connected to the drive housing (10) and the welding gun assembly (8). Y-axis arms (4) are fixedly connected to the lower left and right sides of the main frame (1). Y-axis guide rail (401) is fixedly connected to the upper side of the Y-axis arm (4). A transverse guide rail (11) and a guide rod (13) are fixedly connected to the inner side of the Y-axis arm (4). A sliding clamping block (2) is slidably connected to the transverse guide rail (11). The sliding clamping block (2) and the guide rod (13) are slidably engaged. An elastic reset member (12) is sleeved on the outer side of the guide rod (13). A limit block (3) is fixedly connected to the Y-axis arm (4) at the position outside the sliding clamping block (2). The elastic reset member (12) is located between the sliding clamping block (2) and the limit block (3).

2. The automated welding device for steel structure processing according to claim 1, characterized in that: The main frame (1) includes two supporting bodies spaced apart on the left and right and a transverse connecting part connected between the upper ends of the two supporting bodies. The X-axis arm (5) is fixedly connected to the front side of the transverse connecting part, and the two Y-axis arms (4) are respectively fixedly connected to the opposite inner sides of the lower part of the two supporting bodies. The X-axis arm (5) is fixedly connected to the transverse connecting part and the Y-axis arm (4) is fixedly connected to the supporting body by connecting plates and bolts. The connecting plate is provided with mounting holes, and the diameter of the mounting holes is 0.2-0.5mm larger than the nominal diameter of the corresponding bolts.

3. The automated welding device for steel structure processing according to claim 1, characterized in that: The X-axis guide rail (14) includes two linear guide rails arranged parallel to each other along the length of the X-axis arm (5). The two linear guide rails are fixedly connected to the front side of the X-axis arm (5) by countersunk screws. The rear side of the Z-axis arm (6) is fixedly connected to a mounting plate. The mounting plate is slidably engaged with the two linear guide rails by four sets of sliders. The drive housing (10) is provided with an X-axis lead screw parallel to the X-axis guide rail (14). One end of the X-axis lead screw is connected to the output shaft of the drive motor through a coupling, and the other end is rotatably connected to the end of the X-axis arm (5) through a bearing seat. The Z-axis arm (6) is fixedly connected to a nut seat provided on the X-axis lead screw.

4. The automated welding device for steel structure processing according to claim 1, characterized in that: The workpiece reference recognition and reconstruction module (801) is fixedly connected to the first mounting bracket on the upper front side of the Z-axis arm (6), and the weld recognition device (803) is fixedly connected to the second mounting bracket on the upper side of the Z-axis arm (6). The first mounting bracket and the second mounting bracket are detachably connected to the Z-axis arm (6) by bolts. The detection end of the workpiece reference recognition and reconstruction module (801) and the detection end of the weld recognition device (803) are both set towards the area below the welding head (7), and the center line of the workpiece reference recognition and reconstruction module (801) and the center line of the weld recognition device (803) intersect below the axis of the welding head (7).

5. The automated welding device for steel structure processing according to claim 1, characterized in that: The sliding clamping block (2) is set to two, and the two sliding clamping blocks (2) are respectively set on the two Y-axis arms (4) and arranged opposite to each other. The two limiting blocks (3) are respectively fixedly connected to the side of the two Y-axis arms (4) away from the middle of the main frame (1), and each limiting block (3) is fixedly connected to the corresponding Y-axis arm (4) by bolts through elongated holes.

6. The automated welding device for steel structure processing according to claim 1, characterized in that: The elastic reset member (12) is a compression spring. The elastic reset member (12) is coaxially sleeved on the outside of the guide rod (13). The sliding clamping block (2) has a first spring positioning hole on the side facing the limiting block (3). The limiting block (3) has a second spring positioning hole on the side facing the sliding clamping block (2). The two ends of the elastic reset member (12) are respectively embedded in the first spring positioning hole and the second spring positioning hole.

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