Silencing generator set housing assembly apparatus and method

Abstract

This invention belongs to the field of welding and assembly technology, and discloses a device and method for assembling a silencer generator set casing. The device includes an assembly chamber, a hollow roller frame installed at the lower part of the assembly chamber, and longitudinal beam frames fixedly installed on the left and right inner walls of the assembly chamber above the hollow roller frame. An X-axis linear pre-positioning module is movably installed on the two longitudinal beam frames along the X-axis direction. Several parallel short roller groups are rotatably installed inside the hollow roller frame along the X-axis direction. The short roller groups guide the generator set casing to be welded into the assembly chamber. A back frame is fixedly installed on one outer wall of the X-axis linear pre-positioning module. Two parallel and spaced biaxial linear moving modules are installed on the outer wall of the back frame. Adjustable angle welding components are installed at the drive ends of the biaxial moving modules. Exhaust ducts are installed at the top of the assembly chamber and below the hollow roller frame. This invention can complete the welding and assembly operation of the silencer generator set casing.

Description

Technical Field

[0001] This invention belongs to the field of welding and assembly technology, specifically, it relates to a device and method for assembling the casing of a noise-reducing generator set. Background Technology

[0002] A generator set silencing enclosure is a specially designed soundproof cover. Its core function is to effectively isolate and absorb the high-intensity noise generated by the generator set during operation, thereby significantly reducing noise pollution to operators, the surrounding environment, and adjacent areas, ensuring that the workplace complies with environmental regulations and occupational health and safety standards. Its typical structure mainly consists of a base plate and a U-shaped main shell. The base plate is a notched steel plate used to fix the generator set base and to reserve space for generator set base connecting parts or pipes. The U-shaped shell is formed by integrally molding side plates and a top plate, forming an enclosure on the upper and sides. Its plates mostly adopt a double-layer steel plate sandwich structure, filled with sound-absorbing cotton. The inner steel plate is perforated to enhance sound wave absorption. In addition, the shell also includes detachable front and rear end plates. The front end plate usually integrates a silencing air inlet and a soundproof maintenance door, while the rear end plate is designed with a silencing exhaust channel or louvers to meet the necessary air circulation and heat dissipation requirements of the generator set.

[0003] In the current assembly process of generator set muffler housings, workers need to manually hold a welding torch and insert it into the housing to perform welding operations, connecting the U-shaped housing to the base plate. After the prefabricated U-shaped housing is hoisted onto the base plate and initially aligned, the operator does not immediately tighten it completely to the base plate. Instead, it is initially fixed using temporary supports or spot welding to ensure that it does not shift during welding. Subsequently, the welding torch needs to be inserted through a pre-installed inspection door on the housing or an intentionally omitted end plate opening. Since the internal space is usually narrow and relatively enclosed, forced ventilation must be ensured before welding to allow workers to directly observe the weld quality and promptly remove any potential build-up. To prevent the accumulation of harmful gases, it is necessary to ensure sufficient lighting equipment to avoid obstructing vision and affecting welding operations. During the welding process, operators need to hold a welding torch and continuously weld along the longitudinal joints (i.e., left and right longitudinal joints) connecting the two sides of the U-shaped shell to the base plate until a sealed and stable box structure is finally formed. However, the welding process is carried out in a closed or semi-closed space. Even with ventilation measures, welding fumes will still accumulate at a high level, resulting in low operational safety. Moreover, working in a cramped and uncomfortable posture for a long time can easily cause worker fatigue, leading to hand instability and welding defects such as undercut, incomplete penetration, porosity, slag inclusion, or uneven weld seams. These defects will directly affect the structural strength and sound insulation and sealing performance of the shell. Summary of the Invention

[0004] The purpose of this invention is to provide a device and method for assembling a noise-reducing generator set housing. The housing components, initially welded and fixed, are placed on a short roller conveyor of a hollow roller frame and pushed into the assembly chamber. Then, an X-axis linear pre-positioning module initially adjusts the positions of the two dual-axis linear moving modules on the left and right sides and the adjustable angle welding assembly within the housing. After initial adjustment, the control panel adjusts the working position of the adjustable angle welding assembly according to the inner width of the housing and the joint position. The dual-axis linear moving modules drive the adjustable angle welding assembly to move along the longitudinal joint connecting the two sides of the U-shaped housing to the base plate and perform the welding operation. During welding, the exhaust duct continuously vents smoke, thus solving the problems mentioned in the background art.

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

[0006] A noise-reducing generator set housing assembly device includes an assembly chamber. A hollow roller frame is installed at the lower part of the assembly chamber. Longitudinal beam frames are fixedly installed on the left and right inner walls of the assembly chamber above the hollow roller frame. An X-axis linear pre-positioning module is movably installed on the two longitudinal beam frames along the X-axis. Several parallel short roller groups are rotatably installed inside the hollow roller frame along the X-axis. The short roller groups guide the generator set housing to be welded into the assembly chamber. A back frame is fixedly installed on one outer wall of the X-axis linear pre-positioning module. Two parallel and spaced dual-axis linear moving modules are installed on the outer wall of the back frame. Adjustable angle welding components are installed at the drive ends of the dual-axis moving modules. Exhaust ducts for discharging fumes generated during welding are installed at the top of the assembly chamber and below the hollow roller frame. A PLC control panel is installed on one outer wall of the assembly chamber. The control output terminal of the PLC control panel is electrically connected to the control input terminals of the X-axis linear pre-positioning module, the dual-axis moving module, and the adjustable angle welding components, respectively.

[0007] The following are further optimizations of the above technical solution by the present invention:

[0008] The exhaust duct includes an upper smoke collection duct installed at the center of the top of the assembly compartment, and a lower smoke collection duct installed at the lower opening of the hollow roller frame.

[0009] Further optimization: A C-shaped connecting pipe is installed on one side of the outer wall of the upper flue and at the lower end opening of the lower flue. A main exhaust pipe is installed on the outer wall of the C-shaped connecting pipe away from the assembly compartment.

[0010] Further optimization: The X-axis linear prepositioning module includes a Y-axis straight frame, which is slidably installed on the top of two longitudinal beam frames along the X-axis direction. A linear rack is fixedly installed on the top of each of the two longitudinal beam frames along the X-axis direction. A double gear shaft is rotatably installed inside the Y-axis straight frame through a bearing seat. The two ends of the double gear shaft mesh with the corresponding linear rack through gears.

[0011] Further optimization: A first stepper motor is fixedly installed at the top center of the Y-direction straight frame. The lower end of the power output shaft of the first stepper motor extends to the bottom of the Y-direction straight frame. The power output shaft of the first stepper motor is connected to the double gear shaft through a right-angle bevel gear transmission pair.

[0012] Further optimization: The dual-axis linear movement module includes a servo electric cylinder fixed to the outer wall of one side of the back frame. A slide is installed at the end of the piston rod of the servo electric cylinder. A right-angle arm is fixedly installed on the side of the slide away from the back frame. A fully enclosed belt linear module one is installed on the outer wall of the right-angle arm near the vertical center reference plane of the back frame. A fully enclosed belt linear module two is installed on the moving end of the fully enclosed belt linear module one. An adjustable angle welding assembly is installed on the moving end of the fully enclosed belt linear module two.

[0013] Further optimization: Two steel columns are installed on the back frame at the upper and lower positions of the servo electric cylinder. The steel columns are arranged parallel to the servo electric cylinder. A sliding sleeve is fixedly installed on the outer wall of the slide table on the side away from the right-angle arm. The sliding sleeve is slidably connected to the steel column.

[0014] Further optimization: The adjustable angle welding assembly includes a main hollow arm fixedly installed below the second moving end of the fully enclosed belt linear module. A secondary rotating arm is installed at one end of the main hollow arm via a first rotating shaft. A bracket is installed at the bottom end of the secondary rotating arm via a second rotating shaft. An electric welding gun is installed on one side of the bottom end of the bracket.

[0015] Further optimization: A second stepper motor is fixedly installed on one side inside the main hollow arm. The power output shaft of the second stepper motor is connected to the first rotating shaft through the first gear transmission pair to drive the second-stage rotating arm to rotate. A third stepper motor is installed on the outer wall of one side of the second-stage rotating arm. The power output shaft of the third stepper motor is connected to the second rotating shaft through the second gear transmission pair to drive the bracket to rotate.

[0016] The present invention also provides a method for assembling a housing of a noise-reducing generator set, using the aforementioned equipment for assembling a housing of a noise-reducing generator set, comprising the following steps:

[0017] S101: In the pre-processing area outside the assembly compartment, the workers first operate the overhead crane or gantry crane to smoothly lift the U-shaped shell and base plate assembly, which has been initially aligned and temporarily fixed by spot welding, onto the hollow roller frame. The assembly is then manually pushed into the assembly compartment along the roller conveyor by the short rollers on the hollow roller frame until it reaches the predetermined welding position. Afterwards, the workers prepare for the operation on the PLC control panel, retrieve or input the specification parameters of the current batch of shells, and control the operation path of the X-axis linear pre-positioning module, the dual-axis linear moving module, and the adjustable corner welding assembly.

[0018] S102: The X-axis linear prepositioning module is controlled by the PLC control panel. The X-axis linear prepositioning module spans the assembly compartment and is responsible for large-scale initial positioning. It drives the dual-axis linear moving modules suspended on the left and right sides below it to the starting position that is adapted to the inner width of the shell. Then, the adjustable angle welding components are finely adjusted. The posture and angle of the welding gun are finely adjusted by the staff to ensure that the welding gun is accurately aligned with the two longitudinal seams at the connection between the side plate and the bottom plate of the U-shaped shell.

[0019] S103: Start the welding program on the PLC control panel. The dual-axis linear moving modules on the left and right sides synchronously drive the adjustable angle welding components to move along the entire length of the joint at a constant speed. During the welding process, the exhaust ducts integrated above and below the assembly chamber are powerfully started by the external exhaust fan, which quickly captures and discharges the welding fumes as soon as they are generated. The welding operation on both sides can be completed in one stroke.

[0020] S104: After welding is completed, all parts are reset, and the completed outer shell is pulled out from the workstation in the assembly chamber along the short roller group for visual inspection and verification of key dimensions.

[0021] The present invention, by adopting the above technical solution, has at least the following beneficial effects:

[0022] 1. In this invention, the initially welded and fixed outer shell component is placed on the short roller track of the hollow roller frame and pushed into the assembly chamber. Then, the X-axis linear pre-positioning module initially adjusts the initial positions of the two dual-axis linear moving modules on the left and right sides and the adjustable angle welding component in the outer shell. After the initial debugging is completed, the dual-axis linear moving module and the adjustable angle welding component are used to perform automated welding operations inside the shell, which improves welding quality, reduces the labor intensity of workers, and the matching exhaust duct works continuously during the welding process, efficiently extracting and treating fumes from the source, ensuring the cleanliness of the air in the entire working area. The moving structure composed of the X-axis linear pre-positioning module and the dual-axis moving module can be precisely and repeatedly adjusted according to the inner width of the outer shell and the position of the joint, ensuring that the adjustable angle welding component can always run along the preset path with the optimal posture, constant speed and distance. This eliminates defects such as porosity, slag inclusion, and incomplete penetration caused by worker fatigue, skill differences or poor vision, resulting in higher continuity, uniformity, penetration depth and appearance consistency of the weld, thus improving welding quality.

[0023] 2. In this invention, the parts to be welded are placed on the short roller conveyor of the hollow roller frame and pushed into the assembly chamber, which greatly reduces the auxiliary time such as hoisting and adjustment and personnel entry and exit. By introducing an automated X-axis linear prepositioning module, a dual-axis linear moving module and an adjustable angle welding assembly, the welding process can achieve fast and continuous automated operation, effectively shortening the assembly cycle and improving the overall production efficiency. Attached Figure Description

[0024] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present invention. Figure 1 ;

[0025] Figure 2 This is a side view of the overall structure in an embodiment of the present invention;

[0026] Figure 3 This is a three-dimensional sectional view of the overall structure in an embodiment of the present invention;

[0027] Figure 4 This is a front sectional view of the overall structure in an embodiment of the present invention;

[0028] Figure 5 This is a three-dimensional structural diagram of an embodiment of the present invention. Figure 2 ;

[0029] Figure 6 This is a three-dimensional sectional view of the X-axis linear prepositioning module position in an embodiment of the present invention;

[0030] Figure 7 for Figure 6 A magnified view of a section at point A in the middle;

[0031] Figure 8 This is a three-dimensional structural diagram of the dual-axis linear motion module in an embodiment of the present invention;

[0032] Figure 9 This is a front view of the dual-axis linear motion module in an embodiment of the present invention;

[0033] Figure 10 This is an assembly diagram of the dual-axis linear moving module and the adjustable angle welding assembly in an embodiment of the present invention;

[0034] Figure 11 This is a cross-sectional view of the adjustable corner welding assembly position in an embodiment of the present invention;

[0035] Figure 12 for Figure 11 A magnified view of a section at point B in the middle.

[0036] In the diagram: 1-Assembly compartment; 2-Hollow roller frame; 3-Short roller group; 4-Longitudinal beam frame; 5-X-axis linear pre-positioning module; 501-Y-axis straight frame; 502-First stepper motor; 503-Linear rack; 504-Double gear shaft; 505-Right angle bevel gear transmission pair; 6-Back frame; 601-Steel column; 7-Double axis linear moving module; 701-Servo electric cylinder; 702-Slide table; 703-Right angle arm; 704-Fully enclosed belt linear module one; 705-Fully enclosed belt linear module two ; 8-Adjustable angle welding assembly; 801-Main hollow arm; 802-Secondary rotating arm; 803-Bracket; 804-Welding gun; 805-Second stepper motor; 806-Third stepper motor; 807-First rotating shaft; 808-Second rotating shaft; 809-First gear transmission pair; 810-Second gear transmission pair; 9-PLC control panel; 10-Smoke exhaust duct; 1001-Lower smoke collection duct; 1002-Upper smoke collection duct; 1003-C-type connecting pipe; 1004-Main smoke exhaust pipe. Detailed Implementation

[0037] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0038] like Figures 1 to 5 As shown, a noise-reducing generator set housing assembly device includes an assembly chamber 1. A hollow roller frame 2 is installed at a lower position inside the assembly chamber 1. Longitudinal beam frames 4 are fixedly installed on the left and right inner walls of the assembly chamber 1 above the hollow roller frame 2. An X-axis linear pre-positioning module 5 is movably installed on the two longitudinal beam frames 4 along the X-axis direction. Several parallel short roller groups 3 are rotatably installed inside the hollow roller frame 2 along the X-axis direction. The short roller groups 3 guide the generator set housing to be welded into the assembly chamber 1. A back frame 6 is fixedly installed on one outer wall of the X-axis linear pre-positioning module 5. Two parallel and spaced dual-axis linear moving modules 7 are installed on the outer wall of the back frame 6. Adjustable angle welding components 8 are installed at the drive end of each dual-axis moving module 7. Exhaust ducts 10 for discharging fumes generated during the welding process are installed at the top of the assembly chamber 1 and below the hollow roller frame 2.

[0039] In this embodiment, the assembly chamber 1 is used to provide a safe, controllable and environmentally independent working area, completely isolating the strong light, fumes and arc spatter during the welding process from the external environment, ensuring the safety of personnel outside the chamber and the cleanliness of the overall workshop environment.

[0040] In this embodiment, there are multiple short roller sets 3, and all short roller sets 3 are rotatably mounted on the hollow roller frame 2. The short roller sets 3 are used to guide the generator set housing to be welded into the assembly chamber 1. The multiple short roller sets 3 installed side by side on the hollow roller frame 2 form a low-friction moving plane, which can push the housing assembly after the initial spot welding onto the roller frame, and then easily push it manually into the precise work position in the assembly chamber 1, realizing the efficient and labor-saving transfer of heavy workpieces between work positions.

[0041] A PLC control panel 9 is installed on one side of the outer wall of the assembly compartment 1. The control output terminals of the PLC control panel 9 are electrically connected to the control input terminals of the X-axis linear prepositioning module 5, the dual-axis linear moving module 7, and the adjustable corner welding assembly 8, respectively. The PLC control panel 9 outputs control signals to independently control the corresponding X-axis linear prepositioning module 5, dual-axis linear moving module 7, and adjustable corner welding assembly 8 to work.

[0042] The exhaust duct 10 includes an upper smoke collection duct 1002 installed at the center of the top of the assembly compartment 1, and a lower smoke collection duct 1001 installed at the lower opening of the hollow roller frame 2.

[0043] A C-shaped connecting pipe 1003 is installed on one side of the outer wall of the upper flue 1002 and at the lower end opening of the lower flue 1001. A main exhaust pipe 1004 is installed on the outer wall of the C-shaped connecting pipe 1003 away from the assembly compartment 1.

[0044] In this embodiment, an external exhaust fan is connected to the end of the main exhaust pipe 1004. The upper exhaust duct 1002 is located above the assembly chamber 1, while the lower exhaust duct 1001 is located below the hollow roller frame 2 to form a negative pressure capture zone. The fumes are forcefully sucked in the moment they are generated and discharged through the C-shaped connecting pipe 1003 and the main exhaust pipe 1004 to reduce the harm of welding fumes to equipment and personnel.

[0045] Both the upper chimney 1002 and the lower chimney 1001 are made of stainless steel. Stainless steel has excellent corrosion resistance and can maintain the stability of its physical and chemical properties in high-temperature environments, making it less prone to deformation or damage.

[0046] like Figure 6 and Figure 7 As shown, the X-axis linear prepositioning module 5 includes a Y-axis straight frame 501. The Y-axis straight frame 501 is slidably mounted on the top of two longitudinal beam frames 4 along the X-axis direction via guide rails and sliders. A linear rack 503 is fixedly mounted on the top of each of the two longitudinal beam frames 4 along the X-axis direction. A double gear shaft 504 is rotatably mounted inside the Y-axis straight frame 501 via a bearing seat. The two ends of the double gear shaft 504 mesh with the corresponding linear rack 503 via gears.

[0047] A first stepper motor 502 is fixedly installed at the top center of the Y-direction straight frame 501. The lower end of the power output shaft of the first stepper motor 502 extends to the bottom of the Y-direction straight frame 501. The power output shaft of the first stepper motor 502 is connected to the double gear shaft 504 through a right-angle bevel gear transmission pair 505. When the first stepper motor 502 starts, it drives the double gear shaft 504 to rotate through the right-angle bevel gear transmission pair 505.

[0048] With this design, when the X-axis linear pre-positioning module 5 carries the dual-axis linear moving module 7 and the adjustable angle welding assembly 8 for initial position adjustment, the first stepper motor 502 drives the double gear shaft 504 at the top of the Y-axis straight frame 501 to rotate through the right-angle bevel gear transmission pair 505. Since the ends of the double gear shaft 504 are engaged with the linear rack 503 on the longitudinal beam frame 4, the Y-axis straight frame 501 can drive the dual-axis linear moving module 7 and the adjustable angle welding assembly 8 to move along the length direction of the longitudinal beam frame 4 under the drive of the double gear shaft 504, so as to initially adjust the X-axis position of the dual-axis moving module 7 and the adjustable angle welding assembly 8 inside the housing, which is convenient for use.

[0049] The X-axis linear prepositioning module 5 carries its two sets of adjustable angle welding components 8 suspended on the left and right sides. It moves as a whole along the X-axis length direction of the housing and quickly reaches the predetermined starting area that matches the current workpiece to adapt to housings of different sizes and specifications.

[0050] like Figure 8 , Figure 9 and Figure 10 As shown, the dual-axis linear motion module 7 includes a servo electric cylinder 701 fixedly connected to the outer wall of one side of the back frame 6. A slide table 702 is installed at the piston rod end of the servo electric cylinder 701. A right-angle arm 703 is fixedly installed on the side of the slide table 702 away from the back frame 6. A fully enclosed belt linear module one 704 is installed on the outer wall of the right-angle arm 703 near the vertical center reference plane of the back frame 6. A fully enclosed belt linear module two 705 is installed on the moving end of the fully enclosed belt linear module one 704. An adjustable angle welding assembly 8 is installed on the moving end of the fully enclosed belt linear module two 705.

[0051] In this embodiment, the fully enclosed belt linear module 704 is arranged along the X-axis. When the fully enclosed belt linear module 704 is activated, it drives the fully enclosed belt linear module 705 and the adjustable angle welding assembly 8 to move horizontally in the X-axis direction via the moving end.

[0052] The fully enclosed belt linear module 2 705 is laid out along the Z-axis. When the fully enclosed belt linear module 2 705 is started, the adjustable angle welding component 8 is driven to move up and down in the Z-axis direction through the moving end.

[0053] In this embodiment, both the fully enclosed belt linear module 1 704 and the fully enclosed belt linear module 2 705 are existing technologies and can be purchased directly from the market. Their specific structures will not be described in detail here.

[0054] Two steel columns 601 are installed on the back frame 6 at the upper and lower positions of the servo electric cylinder 701. The steel columns 601 are arranged parallel to the servo electric cylinder 701. Two sliding sleeves are fixedly installed on the outer wall of the slide table 702 away from the right angle arm 703. The two sliding sleeves are arranged at an interval between the upper and lower parts. The sliding sleeves are slidably connected to the steel columns 601.

[0055] With this design, the servo electric cylinder 701 drives the slide table 702, right-angle arm 703, fully enclosed belt linear module one 704, fully enclosed belt linear module two 705, and adjustable angle welding assembly 8 to move along the Y-axis to adapt to the inner width of the shell to be welded. The fully enclosed belt linear module two 705 can drive the adjustable angle welding assembly 8 to move vertically, so that the welding gun can move to the appropriate welding position.

[0056] The fully enclosed belt linear module 704 drives the adjustable angle welding component 8 to perform uniform and precise linear motion along the joint trajectory, so as to achieve rapid and stable completion of the welding task.

[0057] The adjustable angle welding assembly 8 includes a main hollow arm 801 fixedly installed below the moving end of the fully enclosed belt linear module 705. A secondary rotating arm 802 is installed at one end of the main hollow arm 801 via a first rotating shaft 807. A bracket 803 is installed at the bottom end of the secondary rotating arm 802 via a second rotating shaft 808. An electric welding gun 804 is installed on one side of the bottom end of the bracket 803.

[0058] A second stepper motor 805 is fixedly installed on one side inside the main hollow arm 801. The power output shaft of the second stepper motor 805 is connected to the first rotating shaft 807 through the first gear transmission pair 809, which is used to drive the secondary rotating arm 802 to rotate. A third stepper motor 806 is installed on the outer wall of one side of the secondary rotating arm 802. The power output shaft of the third stepper motor 806 is connected to the second rotating shaft 808 through the second gear transmission pair 810, which is used to drive the bracket 803 to rotate.

[0059] In this embodiment, the first gear transmission pair 809 and the second gear transmission pair 810 have the same overall structure, both including two meshing bevel gears. Taking the first gear transmission pair 809 as an example, one bevel gear is fixedly connected to the power output shaft of the second stepper motor 805, and the other bevel gear is fixedly connected to the first rotating shaft 807. When the second stepper motor 805 starts, it can drive the first rotating shaft 807 to rotate through the transmission action of the two meshing bevel gears, thereby driving the secondary rotating arm 802 to rotate.

[0060] With this design, when using the adjustable angle welding assembly 8, the operator controls the second stepper motor 805 and the third stepper motor 806 through the PLC control panel 9. The power output shaft of the second stepper motor 805 drives the first rotating shaft 807 and the secondary rotating arm 802 to rotate through the first gear transmission pair 809. At this time, the secondary rotating arm 802 drives the welding gun 804 to deflect up and down so that the lower end of the welding gun 804 can face the welding position.

[0061] The output shaft of the third stepper motor 806 drives the second rotating shaft 808 and the bracket 803 to rotate through the second gear transmission pair 810, so as to further flexibly adjust the working position of the welding gun 804. Through multi-degree-of-freedom adjustment, the welding gun can always maintain the best welding posture and distance with the joint surface at different angles and positions, thereby improving the welding quality.

[0062] In this embodiment, the PLC control panel 9 is existing technology. Its specific structure includes a PLC main controller and a touch screen. The touch screen is communicatively connected to the PLC main controller. The PLC main controller is used to output control signals or receive feedback and detection signals. The touch screen is used to input debugging control parameters or display control operation parameters.

[0063] The present invention also provides a method for assembling a housing of a noise-reducing generator set, using the above-mentioned assembly equipment for a noise-reducing generator set housing, comprising the following steps:

[0064] S101: In the pre-processing area outside the assembly compartment 1, the workers first operate the overhead crane or gantry crane to smoothly lift the U-shaped shell and base plate assembly, which has been initially aligned and temporarily fixed by spot welding, onto the hollow roller frame 2. The assembly is then manually pushed into the assembly compartment 1 along the roller conveyor by the short roller group 3 on the hollow roller frame 2 until it reaches the predetermined welding position. Afterwards, the workers prepare for the operation on the PLC control panel 9, retrieve or input the specification parameters of the current batch of shells, and control the operation path of the X-axis linear pre-positioning module 5, the dual-axis linear moving module 7, and the adjustable corner welding assembly 8.

[0065] S102: The X-axis linear pre-positioning module 5 is controlled by the PLC control panel 9. The X-axis linear pre-positioning module 5 spans the assembly compartment 1 and is responsible for large-scale initial positioning. It drives the dual-axis linear moving modules 7 suspended on the left and right sides below it to move to the starting position that is compatible with the inner width of the shell. Then, the adjustable angle welding component 8 is finely adjusted. The posture and angle of the welding gun are finely adjusted by the staff to ensure that the welding gun is accurately aligned with the two longitudinal seams at the connection between the side plate and the bottom plate of the U-shaped shell.

[0066] In step S102, the working principle of the X-axis linear prepositioning module 5 is as follows: the first stepper motor 502 starts according to the rotation direction, speed, response time and number of rotations set by the PLC control panel 9. At this time, the first stepper motor 502 drives the double gear shaft 504 to rotate through the right angle bevel gear transmission pair 505. The ends of the double gear shaft 504 are connected to the linear rack 503 on the longitudinal beam frame 4 through gears. At this time, the Y-axis straight frame 501 can drive the double axis linear moving module 7 and the adjustable angle welding assembly 8 to move along the length direction of the longitudinal beam frame 4 under the drive of the double gear shaft 504. The adjustable angle welding assembly 8 moves as a whole along the X-axis length direction of the shell and quickly reaches the predetermined starting area that matches the current workpiece to adapt to shells of different sizes and specifications.

[0067] In step S102, the working principle of the adjustable angle welding assembly 8 is as follows: The PLC control panel 9 controls the second stepper motor 805 and the third stepper motor 806 to start with the set rotation direction, speed, response time and number of rotations. At this time, the second stepper motor 805 starts and drives the first rotating shaft 807 and the secondary rotating arm 802 to rotate through the first gear transmission pair 809. The secondary rotating arm 802 drives the welding gun 804 to deflect up and down so that the lower end of the welding gun 804 can face the welding position. The third stepper motor 806 starts and drives the second rotating shaft 808 and the bracket 803 to rotate through the second gear transmission pair 810, so as to further flexibly adjust the working position of the welding gun 804, so that the welding gun 804 maintains the best welding posture and distance with the joint, thereby improving the welding quality.

[0068] S103: Start the welding program on the PLC control panel 9. The dual-axis linear moving modules 7 on the left and right sides synchronously drive the adjustable angle welding component 8 to move along the entire length of the joint at a constant speed. During the welding process, the exhaust ducts 10 integrated above and below the assembly chamber 1 are powerfully started by the external exhaust fan, which quickly captures and discharges the welding fumes as soon as they are generated. The welding operation on both sides can be completed in one stroke.

[0069] In step S103, the working principle of the dual-axis linear moving module 7 is as follows: First, the PLC control panel 9 controls the servo cylinder 701 to start with the set extension direction, extension distance and response time. The servo cylinder 701 drives the slide table 702, right-angle arm 703, fully enclosed belt linear module one 704, fully enclosed belt linear module two 705 and adjustable angle welding assembly 8 to move along the Y-axis to adapt to the inner width of the shell to be welded. The fully enclosed belt linear module two 705 starts to drive the adjustable angle welding assembly 8 to move vertically up and down, so that the welding gun can move to the appropriate welding position.

[0070] Then, the PLC control panel 9 controls the fully enclosed belt linear module 704 to start with the set moving direction, moving distance, moving speed and response time. The fully enclosed belt linear module 704 drives the adjustable angle welding component 8 to perform uniform and precise linear motion along the joint trajectory, so as to achieve fast and stable completion of the welding task.

[0071] S104: After welding is completed, all parts are reset, and the complete welded shell is pulled out from the workstation in the assembly chamber 1 along the short roller group 3 for visual inspection and verification of key dimensions.

[0072] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from the spirit and scope of this invention; thus, if these modifications and variations of this invention fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A sound attenuating genset enclosure assembly apparatus, characterized by: The assembly compartment (1) includes a hollow roller frame (2) installed at a lower position inside the assembly compartment (1). Longitudinal beam frames (4) are fixedly installed on the left and right inner walls of the assembly compartment (1) above the hollow roller frame (2). An X-axis linear pre-positioning module (5) is movably installed on the two longitudinal beam frames (4) along the X-axis direction. Several parallel short roller groups (3) are installed inside the hollow roller frame (2) and rotate along the X-axis direction. The short roller groups (3) guide the generator set casing to be welded into the assembly compartment (1). A back frame (6) is fixedly installed on one outer wall of the X-axis linear pre-positioning module (5). The back frame (6) has an outer... Two parallel and spaced dual-axis linear moving modules (7) are installed on the wall. Adjustable corner welding components (8) are installed at the drive end of each dual-axis linear moving module (7). Smoke exhaust ducts (10) for discharging fumes generated during welding are installed on the top of the assembly chamber (1) and below the hollow roller frame (2). A PLC control panel (9) is installed on one side of the outer wall of the assembly chamber (1). The control output terminal of the PLC control panel (9) is electrically connected to the control input terminal of the X-axis linear prepositioning module (5), the dual-axis moving module (7), and the adjustable corner welding component (8). The X-axis linear prepositioning module (5) includes a Y-axis straight frame (501), which is slidably installed on the top of two longitudinal beam frames (4) along the X-axis direction. A linear rack (503) is fixedly installed on the top of each of the two longitudinal beam frames (4) along the X-axis direction. A double gear shaft (504) is rotatably installed inside the Y-axis straight frame (501) through a bearing seat. The two ends of the double gear shaft (504) mesh with the corresponding linear rack (503) through gears. A first stepper motor (502) is fixedly installed at the top center of the Y-direction straight frame (501). The lower end of the power output shaft of the first stepper motor (502) extends to the bottom of the Y-direction straight frame (501). The power output shaft of the first stepper motor (502) is connected to the double gear shaft (504) through a right angle bevel gear transmission pair (505). The dual-axis linear moving module (7) includes a servo electric cylinder (701) fixed to the outer wall of one side of the back frame (6). A slide (702) is installed at the piston rod end of the servo electric cylinder (701). A right-angle arm (703) is fixedly installed on the side of the slide (702) away from the back frame (6). A fully enclosed belt linear module one (704) is installed on the outer wall of the right-angle arm (703) near the vertical center reference plane of the back frame (6). A fully enclosed belt linear module two (705) is installed on the moving end of the fully enclosed belt linear module one (704). An adjustable angle welding assembly (8) is installed on the moving end of the fully enclosed belt linear module two (705).

2. The sound attenuating genset enclosure assembly of claim 1, wherein: The exhaust duct (10) includes an upper smoke collection duct (1002) installed at the center of the top of the assembly compartment (1), and a lower smoke collection duct (1001) installed at the lower opening of the hollow roller frame (2).

3. The noise-reducing generator set housing assembly equipment according to claim 2, characterized in that: A C-type connecting pipe (1003) is installed on one side of the outer wall of the upper flue (1002) and at the lower end opening of the lower flue (1001). A main exhaust pipe (1004) is installed on the outer wall of the C-type connecting pipe (1003) away from the assembly compartment (1).

4. A sound attenuating generator set housing assembly according to claim 3, wherein: Two steel columns (601) are installed on the back frame (6) at the upper and lower positions of the servo electric cylinder (701). The steel columns (601) are arranged parallel to the servo electric cylinder (701). A sliding sleeve is fixedly installed on the outer wall of the slide table (702) away from the right-angle arm (703). The sliding sleeve is slidably connected to the steel column (601).

5. A sound attenuating generator set housing assembly according to claim 4, wherein: The adjustable angle welding assembly (8) includes a main hollow arm (801) fixedly installed below the moving end of the fully enclosed belt linear module two (705). One end of the main hollow arm (801) is equipped with a secondary rotating arm (802) via a first rotating shaft (807). The bottom end of the secondary rotating arm (802) is equipped with a bracket (803) via a second rotating shaft (808). A welding gun (804) is installed on one side of the bottom end of the bracket (803).

6. A sound attenuating generator set housing assembly according to claim 5, wherein: A second stepper motor (805) is fixedly installed on one side inside the main hollow arm (801). The power output shaft of the second stepper motor (805) is connected to the first rotating shaft (807) through the first gear transmission pair (809) to drive the secondary rotating arm (802) to rotate. A third stepper motor (806) is installed on the outer wall of one side of the secondary rotating arm (802). The power output shaft of the third stepper motor (806) is connected to the second rotating shaft (808) through the second gear transmission pair (810) to drive the bracket (803) to rotate.

7. A method of assembling a sound attenuating genset enclosure using the sound attenuating genset enclosure assembly apparatus of any one of claims 1-6, the method comprising: Includes the following steps: S101: In the pre-processing area outside the assembly compartment (1), the staff first operate the overhead crane or gantry crane to smoothly lift the U-shaped shell and base plate assembly, which has been preliminarily aligned and temporarily fixed by spot welding, onto the hollow roller frame (2). The assembly is then manually pushed into the assembly compartment (1) along the roller track by the short roller group (3) on the hollow roller frame (2) until it reaches the predetermined welding station. After that, the staff prepares for the operation on the PLC control panel (9), retrieves or inputs the specification parameters of the current batch of shells, and controls the operation path of the X-axis linear prepositioning module (5), the dual-axis linear moving module (7), and the adjustable corner welding assembly (8). S102: The X-axis linear prepositioning module (5) is controlled by the PLC control panel (9) to work. The X-axis linear prepositioning module (5) spans the assembly compartment (1) and is responsible for large-scale preliminary positioning. It drives the dual-axis linear moving modules (7) suspended on the left and right sides below it to move to the starting position that is compatible with the inner width of the shell. Then, the adjustable angle welding assembly (8) is finely adjusted. The posture and angle of the welding gun are finely adjusted by the staff to ensure that the welding gun is accurately aligned with the two longitudinal seams at the connection between the side plate and the bottom plate of the U-shaped shell. S103: Start the welding program on the PLC control panel (9). The dual-axis linear moving modules (7) on the left and right sides synchronously drive the adjustable angle welding assembly (8) to move along the entire length of the joint at a constant speed. During the welding process, the exhaust ducts (10) integrated above and below the assembly chamber (1) are powerfully started by the external exhaust fan. The welding fumes are quickly captured and discharged as soon as they are generated. The long seams on both sides can complete the welding operation in one stroke. S104: After welding is completed, each part is reset and the completed shell is pulled out from the workstation in the assembly chamber (1) along the short roller group (3) for visual inspection and verification of key dimensions.

Images