Welding workstation and welding method

Abstract

The invention discloses a welding work station and a welding method, and relates to the technical field of welding, the welding work station comprises a three-axis positioner, at least two welding robots and a control system, each welding robot is arranged at the welding work station, the three-axis positioner is provided with two clamping positions, and the two clamping positions are each provided with a tool clamp used for clamping and fixing a cross beam; the two clamping positions can alternately switch and move between the feeding and discharging station and the welding station so that workpiece clamping and welding operation can be carried out in parallel. The position of the tool clamp at the clamping position can be adjusted, so that the tool clamp can be suitable for clamping and fixing operation of cross beams of various specifications, and frequent clamp replacement or layout adjustment is not needed. The control system is in communication connection with the welding robot and the three-axis positioner and used for controlling the alternate switching action of the two clamping positions and the welding action of the welding robot. Through cooperation of the multiple welding robots and comprehensive application of the three-axis positioner and the flexible tool clamp, the production efficiency is remarkably improved, and the welding quality is guaranteed.

Description

Technical Field

[0001] This application relates to the field of welding technology, and more specifically, to a welding workstation and welding method. Background Technology

[0002] With the rapid development of the photovoltaic industry, flexible photovoltaic (PV) supports are increasingly widely used in complex terrains such as fishponds due to their strong adaptability. In the structure of flexible PV supports, the long continuous crossbeam in the middle is mainly used in scenarios with small row spacing to span multiple rows. This long continuous crossbeam is usually made of large-section profiles such as HN300 steel, and its length is relatively large, reaching up to 8 meters, and its overall weight is relatively heavy.

[0003] To meet structural strength and functional requirements, several reinforcing plates, connecting plates, and shims need to be welded onto the long continuous crossbeam. The reinforcing plates and connecting plates are used to increase the rigidity of the long continuous crossbeam and provide fixing holes for the wind-resistant cables. The shims are used to provide a height difference between the two main cables, thereby providing the required tilt angle for the photovoltaic modules. These components are all important welding objects on the long continuous crossbeam.

[0004] Currently, welding operations for such large and heavy workpieces mainly rely on manual welding. However, this method has significant drawbacks: the large length of the workpiece leads to low production efficiency; at the same time, welding quality is difficult to guarantee, especially when handling long and heavy workpieces. The instability of manual operation can result in inconsistent weld joint strength, which in turn affects the structural safety and service life of the entire photovoltaic support structure.

[0005] Therefore, how to achieve stable and efficient welding of long continuous crossbeams in flexible photovoltaic brackets has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] In view of this, the purpose of this application is to provide a welding workstation to achieve stable and efficient welding operations on long continuous crossbeams in flexible photovoltaic brackets.

[0007] Another objective of this application is to provide a welding method for welding mounting plates to a crossbeam using the aforementioned welding workstation.

[0008] A welding workstation for welding mounting plates to a crossbeam includes:

[0009] The three-axis positioner has two clamping positions, which can alternate between the loading / unloading station and the welding station. Both clamping positions are equipped with tooling fixtures for clamping and fixing the crossbeam, and the position of the tooling fixtures at the clamping positions is adjustable.

[0010] At least two welding robots are provided, each of which is movably disposed at the welding station along a first direction and is used to weld the crossbeam and the mounting plate located at the welding station.

[0011] The control system is communicatively connected to the welding robot and the three-axis positioner, and is used to control the alternating switching action of the two clamping positions and the welding action of the welding robot.

[0012] In some embodiments, the tooling fixture includes a first clamping assembly, a second clamping assembly, and a third clamping assembly. The first clamping assembly, the second clamping assembly, and the third clamping assembly are all disposed at the clamping position. The first clamping assembly is used to clamp and fix the crossbeam along the first direction, the second clamping assembly is used to clamp and fix the crossbeam along the second direction, and the third clamping assembly is used to clamp and fix the crossbeam along the third direction. The first direction, the second direction, and the third direction are arranged at an angle to each other. The crossbeam is arranged at the clamping position along the first direction.

[0013] The clamping position is provided with an adjustment guide rail extending along the first direction, and a first adjustment slider is slidably provided on the adjustment guide rail, with at least a portion of the first clamping component disposed on the first adjustment slider.

[0014] In some embodiments, the first clamping component includes:

[0015] At least two support rollers are provided, which are rotatably disposed at the clamping position and are spaced apart along the first direction, and the crossbeam is provided on the support rollers;

[0016] A first positioning substrate is disposed at the clamping position;

[0017] A first clamping member is disposed on the first adjusting slider. The first clamping member and the first positioning base plate are arranged opposite to each other along the first direction and are used to clamp and fix the two ends of the crossbeam along the first direction.

[0018] In some embodiments, a second adjusting slider is slidably disposed on the adjusting guide rail, and each of the supporting rollers is rotatably disposed on the second adjusting slider in a corresponding manner;

[0019] And / or, a third adjusting slider is slidably provided on the adjusting guide rail, and the first positioning base plate is disposed on the third adjusting slider.

[0020] In some embodiments, the second clamping assembly includes a second positioning base plate and a second clamping member arranged opposite to each other along the second direction, and the second positioning base plate and the second clamping member are used to clamp and fix the crossbeam on both sides along the second direction.

[0021] The second clamping component is at least one and is disposed on the second adjusting slider.

[0022] In some embodiments, there is at least one third clamping assembly, and the third clamping assembly includes a flip-over avoidance drive and a third clamping member. The flip-over avoidance drive is disposed on the second adjusting slider, and the third clamping member is rotatably disposed on the second adjusting slider and connected to the power output end of the flip-over avoidance drive. The flip-over avoidance drive is used to drive the third clamping member to rotate so as to press the crossbeam against the support roller, or to make the third clamping member avoid the loading and unloading action of the crossbeam at the clamping position.

[0023] In some embodiments, the first adjusting slider is provided with a first fastener, which is used to abut against the adjusting guide rail for locking or insertion limiting.

[0024] And / or, the second adjusting slider is provided with a second fastener, which is used to abut against the adjusting guide rail for locking or insertion limiting;

[0025] And / or, the third adjusting slider is provided with a third fastener, which is used to abut against the adjusting guide rail for locking or insertion limiting.

[0026] In some embodiments, the triaxial positioner includes:

[0027] Base;

[0028] A first rotating shaft and a first driving mechanism, wherein the first rotating shaft is rotatably mounted on the base by the drive of the first driving mechanism, and the first rotating shaft is connected to a displacement frame;

[0029] The second and third rotating shafts are rotatably disposed on opposite sides of the displacement frame, and each of the second and third rotating shafts is provided with a clamping position.

[0030] A second drive mechanism and a third drive mechanism, wherein the second drive mechanism is used to drive the second rotating shaft to rotate, and the third drive mechanism is used to drive the third rotating shaft to rotate, and the first rotating shaft, the second rotating shaft and the third rotating shaft all extend along the first direction.

[0031] In some embodiments, the welding robot is equipped with a welding torch for welding the crossbeam and the mounting plate, and a vision sensor is provided on the side of the welding torch, with the acquisition end of the vision sensor facing the front of the welding torch.

[0032] The vision sensor is communicatively connected to the control system and is used to acquire image data and guide the welding torch to track the weld seams of the crossbeam and the mounting plate in real time.

[0033] In some embodiments, the welding workstation further includes a safety light curtain, a transmitting sensor, and a receiving sensor. The safety light curtain enclosure is set in the periphery of the welding station and has an entrance / exit. The transmitting sensor and the receiving sensor are set at the entrance / exit. The transmitting sensor is used to emit a detection beam to the receiving sensor. The receiving sensor is communicatively connected to the control system. If the receiving sensor does not receive the detection beam from the transmitting sensor, the control system controls the welding robot to stop moving.

[0034] A welding method, characterized in that it is used to weld the mounting plate to the crossbeam via a welding workstation as described in any one of the above claims, wherein the welding gun of the welding robot is equipped with a vision sensor, the vision sensor being used to collect the weld contour point cloud data of the crossbeam and the mounting plate in real time and transmit it to the control system; including the following steps:

[0035] Path planning and parameter setting: Using the structural model of the crossbeam and the mounting plate, the surface where the weld is located is unfolded and laid out, and a three-dimensional starting point, a three-dimensional ending point and a collision avoidance point are set to generate the theoretically optimal welding path of the welding robot; When the welding robot passes the collision avoidance point, the three-axis positioner performs a motion to stop or adjust to a preset angle, with the goal of minimizing the number of motions of the three-axis positioner.

[0036] Real-time welding and deviation correction: The welding robot welds along the theoretically optimal welding path. The control system extracts the bevel features of the weld seam based on the point cloud data scanned by the vision sensor, and adjusts the welding process of the welding robot in real time based on the bevel features. The bevel features include bevel width, bevel depth, bevel centerline, and bevel angles on both sides.

[0037] In some embodiments, in the step, before the three-axis positioner performs the action of adjusting to the preset angle, the control system determines whether there is a welding robot currently in operation.

[0038] If present, the three-axis positioner will wait until all the welding robots in operation have completed their current actions before performing the adjustment to the preset angle.

[0039] In some embodiments, the real-time adjustment of the welding process of the welding robot based on the bevel features in the above steps specifically includes the following steps:

[0040] The welding torch height is adjusted. The control system determines whether the bevel width or bevel depth changes abruptly. If so, it further determines whether the number of abrupt changes within a continuous time exceeds a preset threshold. If the number of abrupt changes exceeds the preset threshold, the position of the tool center point of the welding torch along the welding torch axis is adjusted to ensure that the welding wire extension length remains constant.

[0041] For weld seam tracking adjustment, the control system calculates the weld seam tracking deviation in real time based on the distance between the bevel centerline and the theoretical optimal welding path. If the weld seam tracking deviation is greater than the deviation threshold, the control system sends a signal to the welding robot and corrects the two-dimensional position of the tool center point of the welding torch in the plane of the weld seam in real time to ensure that the welding wire is always aligned with the root of the bevel.

[0042] In some embodiments, the steps further include:

[0043] The control system determines whether the angles on both sides of the bevel are symmetrical. If they are not symmetrical, the control system adjusts the welding torch to the side with the smaller angle.

[0044] In some embodiments, in the step, different deviation thresholds are set according to the location of the weld on the crossbeam;

[0045] The deviation threshold is set based on the degree of influence of weld quality at different locations on the stability of the beam structure.

[0046] In some embodiments, the beam includes an interconnected web and flanges, wherein the allowable deviation threshold for the welds on the web is less than the allowable deviation threshold for the welds on the flanges.

[0047] The welding workstation provided in this application includes a three-axis positioner, at least two welding robots, and a control system. Each welding robot is movably positioned at a welding station along a first direction. The three-axis positioner has two clamping positions, each equipped with a fixture for clamping and fixing a crossbeam. The two clamping positions can alternately switch between a loading / unloading position and a welding position. By switching the positions of the two clamping positions between the loading / unloading position and the welding position, workpiece clamping and welding operations can be performed in parallel. Specifically, the clamping position at the loading / unloading position clamps and fixes the crossbeam and mounting plate that have not yet been welded using the fixture. The mounting plate can be pre-installed on the crossbeam by spot welding. The clamped and fixed crossbeam and mounting plate at the welding position are welded together by the welding robot. The control system is communicatively connected to the welding robots and the three-axis positioner and is used to control the alternating switching of the two clamping positions and the welding actions of the welding robots. The tooling fixture is adjustable in position, which can be adapted to clamping and fixing of beams of various specifications without the need for frequent fixture changes or layout adjustments, making it highly versatile.

[0048] Compared to related technologies, the welding workstation provided in this application significantly improves production efficiency and ensures welding quality through the integrated application of multiple welding robots working together, a three-axis positioner, and flexible tooling fixtures. Specifically, the welding workstation uses multiple welding robots to weld simultaneously, distributing the workload through parallel operations. Each welding robot can operate under optimized parameters, thereby shortening the production cycle, improving welding quality, and reducing equipment maintenance costs. Simultaneously, the introduction of a three-axis positioner enables synchronized welding and loading / unloading operations, effectively utilizing idle time in the process, improving production continuity, and reducing energy consumption and reliance on manpower. Furthermore, the welding workstation is equipped with adjustable flexible tooling fixtures, capable of flexibly adapting to beams of various lengths from meters to meters, offering strong versatility. This reduces operational complexity and costs while ensuring the stability and consistency of welding quality for workpieces of various specifications. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments or related technologies of this application, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] Figure 1 Isometric view of the welding workstation disclosed in the embodiments of this application Figure 1 ;

[0051] Figure 2 for Figure 1 A magnified view of a section at point A in the middle;

[0052] Figure 3 for Figure 1 A magnified view of a section at point B in the middle;

[0053] Figure 4 for Figure 1 A magnified view of a section at point C;

[0054] Figure 5 Isometric view of the welding workstation disclosed in the embodiments of this application Figure 2 ;

[0055] Figure 6 This is a front view of the welding workstation disclosed in the embodiments of this application;

[0056] Figure 7 This is a top view of the welding workstation disclosed in the embodiments of this application;

[0057] Figure 8 for Figure 7 A magnified view of a section at point D;

[0058] Figure 9 for Figure 7 A magnified view of a section at point E in the middle;

[0059] Figure 10 Isometric view of the welding workstation disclosed in the embodiments of this application Figure 3 ;

[0060] Figure 11 for Figure 10 A magnified view of a section at point F.

[0061] Among them, 100 is a three-axis positioner, 101 is an adjusting guide rail, 102 is a first adjusting slider, 103 is a second adjusting slider, 104 is a first fastener, 105 is a rotating handle, 110 is a base, 120 is a first rotating shaft, 121 is a positioner frame, 130 is a second rotating shaft, and 140 is a third rotating shaft.

[0062] 200 is a welding robot, and 210 is a translation guide rail;

[0063] 300 is the control system;

[0064] 400 is a tooling fixture, 410 is a first clamping assembly, 411 is a support roller, 412 is a first positioning base plate, 413 is a first clamping member, 414 is a first driving member, 415 is a first push plate, 420 is a second clamping assembly, 421 is a second positioning base plate, 422 is a second clamping member, 430 is a third clamping assembly, 431 is a flipping and avoidance driving member, and 432 is a third clamping member;

[0065] 500 is the crossbeam, and 510 is the mounting plate.

[0066] 600 is a safety light curtain;

[0067] 700 is for the hanger;

[0068] 800 is the installation base. Detailed Implementation

[0069] This application discloses a welding workstation for achieving stable and efficient welding operations on long continuous crossbeams in flexible photovoltaic supports.

[0070] Another aspect of this application is to provide a welding method for welding mounting plates to a crossbeam using the aforementioned welding workstation.

[0071] The embodiments will now be described with reference to the accompanying drawings. Furthermore, the embodiments shown below do not limit the scope of the invention as described in the claims. Additionally, the complete contents of the structures represented in the embodiments below are not limited to those necessary for the solution of the invention as described in the claims. It should be noted that, for ease of description, only the parts relevant to the invention are shown in the drawings. Unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0072] With the rapid development of the photovoltaic industry, flexible photovoltaic brackets are increasingly widely used in complex terrains such as fishponds due to their strong adaptability. The core component, the long continuous crossbeam, is typically manufactured using large-section profiles such as HN300 steel, reaching lengths of up to 8 meters and possessing considerable weight. It requires welding reinforcing plates, connecting plates, and shims to meet strength and functional requirements. However, existing manual welding methods suffer from drawbacks due to the large size and weight of the workpieces. These drawbacks include cumbersome operations, frequent relocation leading to extended auxiliary time, inaccurate positioning affecting welding quality, and the extreme physical exertion and safety hazards associated with manual flipping, as well as inconsistent precision. These issues severely restrict production efficiency and product quality. Therefore, this application discloses a welding workstation and welding method to achieve automated welding of such workpieces, effectively solving the problems of manual operation and ensuring efficient, stable, and safe welding.

[0073] Combination Figure 1 , Figure 5 , Figure 6 and Figure 7The welding workstation disclosed in this application embodiment is used to weld mounting plate 510 onto crossbeam 500. The welding workstation includes a three-axis positioner 100, at least two welding robots 200, and a control system 300. Each welding robot 200 is movably arranged at the welding station along the first direction X. The three-axis positioner 100 has two clamping positions. Each clamping position is provided with a tooling fixture 400 for clamping and fixing the crossbeam 500. The two clamping positions can alternately switch between the loading / unloading position and the welding position. By switching the positions of the two clamping positions between the loading / unloading position and the welding position, the workpiece clamping and welding operations can be performed in parallel. Specifically, the clamping position at the loading / unloading station uses a tooling fixture 400 to clamp and fix the crossbeam 500 and mounting plate 510, which have not yet undergone welding. The mounting plate 510 can be pre-installed on the crossbeam 500 by spot welding. Meanwhile, the clamped crossbeam 500 and mounting plate 510 at the welding station are welded together by the welding robot 200. The control system 300 communicates with the welding robot 200 and the three-axis positioner 100, and is used to control the alternating switching between the two clamping positions and the welding actions of the welding robot 200. The position of the tooling fixture 400 at the clamping position is adjustable, thus adapting to the clamping and fixing operations of crossbeams 500 of various specifications without frequent fixture changes or layout adjustments, demonstrating strong versatility.

[0074] Compared to existing technologies, the welding workstation disclosed in this application significantly improves production efficiency and ensures welding quality through the integrated application of multiple welding robots 200 working together, a three-axis positioner 100, and a flexible tooling fixture 400. Specifically, the welding workstation uses multiple welding robots 200 to weld simultaneously, distributing the workload through parallel operations. Each welding robot 200 can operate under optimized parameters, thereby shortening the production cycle, improving welding quality, and reducing equipment maintenance costs. Simultaneously, the introduction of the three-axis positioner 100 enables synchronized welding and loading / unloading operations, effectively utilizing idle time in the process, improving production continuity, and reducing energy consumption and reliance on manpower. Furthermore, the welding workstation is equipped with an adjustable flexible tooling fixture 400, capable of flexibly adapting to various beam lengths 500 ranging from 2 meters to 8 meters. Its strong versatility reduces operational complexity and cost while ensuring the stability and consistency of welding quality for workpieces of various specifications.

[0075] It should be noted that, in this application, "communication connection" refers to a data exchange path or connection relationship established between devices, enabling them to transmit information to each other. Such a connection can be achieved in various ways, including physical connections via cables, wireless connections using radio waves, infrared rays, microwaves or other wireless technologies, and network connections based on network protocols.

[0076] In some embodiments disclosed in this application, the tooling fixture 400 includes a first clamping assembly 410, a second clamping assembly 420, and a third clamping assembly 430. All three assemblies are disposed at the aforementioned clamping positions. The first clamping assembly 410 is used to clamp and fix the crossbeam 500 along a first direction X; the second clamping assembly 420 is used to clamp and fix the crossbeam 500 along a second direction Y; and the third clamping assembly 430 is used to clamp and fix the crossbeam 500 along a third direction Z. The first direction X, the second direction Y, and the third direction Z are arranged at angles to each other. Figure 1 The diagram illustrates a technical solution where the first direction X, the second direction Y, and the third direction Z are arranged perpendicularly in pairs. A crossbeam 500 is positioned along the first direction X at the clamping location; that is, the length direction of the crossbeam 500 is parallel to the first direction X, the width direction is parallel to the second direction Y, and the height direction is parallel to the third direction Z. This embodiment uses a first clamping assembly 410, a second clamping assembly 420, and a third clamping assembly 430 to collaboratively clamp and fix the crossbeam 500 from three different directions, achieving omnidirectional rigid constraint and precise positioning of the crossbeam 500 in space. This multi-directional clamping structure can effectively resist the complex deformation forces and thermal stresses generated during welding, significantly enhancing the clamping stability and deformation resistance of the crossbeam 500, thereby ensuring the weld formation quality and positional accuracy.

[0077] In addition, the clamping position is provided with an adjusting guide rail 101 extending along the first direction X. A first adjusting slider 102 is slidably disposed on the adjusting guide rail 101. At least part of the first clamping assembly 410 is disposed on the first adjusting slider 102, thereby adapting to crossbeams 500 of different lengths. The adjusting guide rail 101 can adopt various cross-sectional shapes such as T-shaped or dovetail-shaped. The first adjusting slider 102 is adapted to the cross-sectional shape of the adjusting guide rail 101 to simultaneously achieve sliding fit and snap-fit ​​assembly.

[0078] In some embodiments, combined with Figure 3 and Figure 4The first clamping assembly 410 includes at least two support rollers 411, a first positioning base plate 412, and a first clamping member 413. The support rollers 411 are rotatably disposed in the clamping position, and each support roller 411 is spaced apart along a first direction X. A crossbeam 500 is disposed on the support rollers 411. The first clamping member 413 and the first positioning base plate 412 are arranged opposite to each other along the first direction X, and the first positioning base plate 412 is disposed in the clamping position, while the first clamping member 413 is disposed on the first adjusting slider 102. The first clamping member 413 and the first positioning base plate 412 are... 2 is used to clamp and fix the two ends of the crossbeam 500 along the first direction X; and the first clamping member 413 can push the crossbeam 500 towards the direction of the first positioning base plate 412 until the crossbeam 500 is clamped between the first positioning base plate 412 and the first clamping member 413. At the same time, during the process of pushing the crossbeam 500 towards the first positioning base plate 412, the crossbeam 500 rolls on the support roller 411, thereby reducing the moving resistance of the crossbeam 500 and facilitating the clamping of the crossbeam 500 by the first clamping member 413 and the first positioning base plate 412. The first clamping member 413 can move a wide range of positions on the adjusting guide rail 101 with the first adjusting slider 102, thereby adapting to crossbeams 500 of different lengths.

[0079] Specifically, in combination Figure 2 and Figure 8 The first clamping member 413 may include a first driving member 414 and a first push plate 415. The first driving member 414 is a power component such as a cylinder or hydraulic cylinder, and is installed on the first adjusting slider 102 using fasteners such as bolts and pins. The first push plate 415 is installed on the power output end of the first driving member 414. The first driving member 414 can drive the first push plate 415 to abut against the end face of the first end of the crossbeam 500 along the length direction, until the end face of the second end of the crossbeam 500 is pushed onto the first positioning base plate 412, thereby achieving clamping. Elastic buffer pads for abutting against the end face of the crossbeam 500 can be provided on the first push plate 415 and the first positioning base plate 412 to avoid rigid contact and reduce wear.

[0080] Furthermore, a second adjusting slider 103 is slidably provided on the adjusting guide rail 101, and each support roller 411 is slidably and rollingly provided on the second adjusting slider 103, thereby facilitating the adjustment of the support position of each support roller 411 according to the specific length of the crossbeam 500 to be welded, while avoiding interference with the first clamping member 413.

[0081] The first positioning base plate 412 can be fixedly installed in the clamping position by means of bolt connection or other methods. Alternatively, a third adjusting slider can be slidably provided on the adjusting guide rail 101, with the first positioning base plate 412 disposed on the third adjusting slider, thereby adjusting the positioning reference position of the crossbeam 500 in the clamping position along the first direction X. The second adjusting slider 103 and the third adjusting slider can adopt the same structure as the first adjusting slider 102, and will not be described in detail here.

[0082] Combination Figure 3 and Figure 9 The second clamping assembly 420 may include a second positioning base plate 421 and a second clamping member 422 arranged opposite to each other along the second direction Y. The second positioning base plate 421 and the second clamping member 422 are used to clamp and fix the crossbeam 500 on both sides along the second direction Y. In order to adapt to crossbeams 500 of different lengths, there is at least one second clamping assembly 420, and each second clamping assembly 420 is respectively arranged on each of the above-mentioned second adjusting sliders 103. By sliding the second adjusting slider 103 on the adjusting guide rail 101, the second clamping assembly 420 and the support roller 411 can be simultaneously driven to adjust their positions, thereby improving the adjustment efficiency. The second clamping member 422 may include a second driving member and a second push plate. The second driving member is fastened to the second adjusting slider 103 using fasteners such as bolts and pins. The second push plate is disposed at the power output end of the second driving member and is used to abut against the side of the crossbeam 500 along the second direction Y. Furthermore, elastic buffer pads are provided on the sides of the second positioning base plate 421 and the second push plate used to clamp the crossbeam 500 to prevent damage caused by rigid contact between the second positioning base plate 421 and the second push plate and the crossbeam 500.

[0083] The crossbeam 500 is mainly hoisted and lowered at the loading / unloading station by a crane. In other words, the crossbeam 500 is primarily lifted or lowered vertically. To avoid the third clamping assembly 430 interfering with the loading / unloading of the crossbeam 500, combined with... Figure 4 and Figure 9At least one third clamping assembly 430 is provided, and multiple third clamping assemblies 430 are arranged at intervals along the first direction X at the clamping position. Each third clamping assembly 430 includes a tilting and avoidance drive 431 and a third clamping member 432. The tilting and avoidance drive 431 is disposed on the second adjusting slider 103, and the third clamping member 432 is rotatably disposed on the second adjusting slider 103 and connected to the power output end of the tilting and avoidance drive 431. The tilting and avoidance drive 431 can drive the third clamping member 432 to rotate to press the crossbeam 500 against the support roller 411, and drive the third clamping member 432 to tilt to avoid the crossbeam 500 at the clamping position for loading and unloading. The tilting and avoidance drive 431 can be a power component such as a cylinder or a hydraulic cylinder. The second clamping assembly 420 and the third clamping assembly 430 can be disposed on the same second adjusting slider 103 or on different second adjusting sliders 103, and this application does not impose any restrictions on this.

[0084] To position the first adjusting slider 102 on the adjusting guide rail 101 after position adjustment, the first adjusting slider 102 is provided with a first fastener 104. The first fastener 104 abuts against the adjusting guide rail 101 to achieve a tight fixation through friction. Alternatively, the adjusting guide rail 101 is provided with a positioning hole along the first direction X for insertion and mating with the first fastener 104, thereby preventing the first adjusting slider 102 from moving on the adjusting guide rail 101. For example, the first fastener 104 can be a locking screw that is threaded into the first adjusting slider 102. This locking screw can be tightened and pressed against the adjusting guide rail 101 by screwing, thereby fixing the position of the first adjusting slider 102. To facilitate the rotation of the first fastener 104, a rotating handle 105 can also be coaxially fixed to the first fastener 104 for manual operation by the operator. The first fastener 104 can also be a spring plunger, a positioning pin, or other structure, and the first adjusting slider 102 is positioned on the adjusting guide rail 101 by inserting it into the positioning hole, making operation convenient.

[0085] Similarly, the second adjusting slider 103 and the third adjusting slider can be positioned at different positions on the adjusting guide rail 101 using the same scheme as the first adjusting slider 102, which will not be described in detail here.

[0086] In a specific clamping and fixing process, the crossbeam 500 is hoisted to the loading / unloading station by a crane. The first clamping member 413 moves and pre-pushes the crossbeam 500 for coarse positioning, and then retracts. At this time, the second clamping member 422 moves to clamp the crossbeam 500 onto the second positioning base plate 421. Subsequently, the first clamping member 413 moves again to clamp the crossbeam 500 onto the first positioning base plate 412. Finally, the flipping and avoidance drive member 431 drives the third clamping member 432 to clamp the crossbeam 500 onto the support roller 411, completing the clamping. In this clamping process, the coarse positioning of the first clamping member 413 can quickly achieve the initial positioning of the crossbeam 500, greatly shortening the adjustment time in the clamping process. On this basis, the precise clamping of each clamping component can eliminate positioning errors and ensure the stability and accuracy of the final clamping.

[0087] In some embodiments disclosed in this application, combined with Figure 10 and Figure 11 The three-axis positioner 100 includes a base 110, a first rotating shaft 120, a first drive mechanism, a second rotating shaft 130, a third rotating shaft 140, a second drive mechanism, and a third drive mechanism. The base 110 is used to mount on a mounting base 800 such as the ground or a workbench. The first rotating shaft 120 is rotatably mounted on the base 110 along a first direction X, and the first drive mechanism can drive the first rotating shaft 120 to rotate around its own axis. A positioner frame 121 is connected to the first rotating shaft 120, and the rotation of the first rotating shaft 120 can drive the positioner frame 121 to rotate synchronously. The second rotating shaft 130 and the third rotating shaft 140 are respectively rotatably mounted on opposite sides of the positioner frame 121, and the second rotating shaft 130... Each of the aforementioned clamping positions is provided on the first and third rotating shafts 120 and 140. Through the rotation of the first rotating shaft 120, the second and third rotating shafts 130 and 140 synchronously rotate around the axis of the first rotating shaft 120, thereby enabling the two clamping positions to alternately switch between the loading / unloading station and the welding station. A second drive mechanism drives the second rotating shaft 130 to rotate around its own axis, and a third drive mechanism drives the third rotating shaft 140 to rotate around its own axis, so that the clamping position at the welding station can drive the already clamped crossbeam 500 and mounting plate 510 to rotate, thereby adapting the welding position of the mounting plate 510 and the crossbeam 500 to the welding posture of the welding robot 200, improving welding efficiency. The cross-sectional shapes of the first rotating shaft 120, second rotating shaft 130, and third rotating shaft 140 can be regular or irregular shapes such as circles or rectangles; this application does not limit this.

[0088] Combination Figure 7A translation guide rail 210 extending along the first direction X is set on the installation base 800 such as the ground or workbench. The welding robot 200 is movably set on the translation guide rail 210. Each welding robot 200 can be arranged on different translation guide rails 210 or share the same translation guide rail 210. Among them, the layout method of sharing the translation guide rail 210 can effectively save space resources and reduce equipment configuration costs.

[0089] The welding workload of different welding robots 200 can be the same or different. Taking two welding robots 200 as an example, the one with a larger workload is the main machine and the other is the auxiliary machine. When the main machine starts welding, the auxiliary machine starts working simultaneously. After the auxiliary machine finishes its work, it moves to the origin of the translation guide rail 210 or other set safe position to standby. After both the main machine and the auxiliary machine finish their work, the control system 300 controls the three-axis positioner 100 to rotate to switch work positions, and then the main machine and the auxiliary machine continue to carry out a new round of welding operations.

[0090] The welding robot 200 is equipped with a welding torch for welding the crossbeam 500 and the mounting plate 510. A vision sensor is mounted on the side of the welding torch, with its acquisition end located in front of the welding torch's travel path and communicating with the control system 300. This vision sensor can pre-acquire image data of the weld seam ahead, identify the weld seam's position and deviation in advance, and then guide the welding torch in real time to accurately track the weld seam of the crossbeam 500 and the mounting plate 510. Furthermore, by acquiring weld seam information in advance at a forward position, the control system 300 can complete path planning and deviation correction before the welding torch arrives, effectively solving the welding lag problem and ensuring continuous, high-precision real-time tracking of the weld seam of the crossbeam 500 and the mounting plate 510. Specifically, the vision sensor can be a laser sensor, a structured light sensor, a binocular vision sensor, etc.

[0091] To ensure the safety of the welding process, combined with Figure 1 The welding workstation also includes a safety light curtain 600, a transmitting sensor, and a receiving sensor. The safety light curtain 600 is set up around the welding station and has entrances and exits for workers to enter and exit the area. The transmitting sensor and the receiving sensor are set at the entrances and exits. The transmitting sensor can emit a detection beam to the receiving sensor. The detection beam is used to detect whether personnel have entered or exited the safety light curtain 600. The receiving sensor is communicatively connected to the control system 300. If the receiving sensor does not receive the detection beam from the transmitting sensor, that is, if the detection beam is blocked, the control system 300 controls the welding robot 200 to stop moving to ensure the safety of the workers.

[0092] Combination Figure 1The welding workstation includes a hanger 700, which is used to suspend and manage cables and air pipes that move with the welding process.

[0093] For ease of description, the clamping position at the second rotating shaft 130 is defined as the first clamping position and the clamping position at the second rotating shaft 130 is defined as the second clamping position.

[0094] In a specific welding process, a crane lifts the crossbeam 500 to the first clamping position of the three-axis positioner 100 at the loading / unloading station. At this time, the tooling fixture 400 of the first clamping position is in a position to avoid affecting the lowering of the crossbeam 500. Then, the first clamping member 413 starts and pushes the crossbeam 500 onto the first positioning base plate 412 along the first direction X, and then retracts for rough positioning. The second clamping member 422 then starts and pushes the crossbeam 500 onto the second positioning base plate 421. Finally, the first clamping member 413 and the third clamping member 432 clamp and fix the crossbeam 500. Then, the mounting plate 510 to be welded is pre-tack welded to the corresponding position on the crossbeam 500. Then, the first drive mechanism of the three-axis positioner 100 drives the first rotating shaft 120 to rotate, and the first clamping position... The crossbeam 500, along with the welding beam 500, rotates to the welding station near the welding robot 200. Simultaneously, the second clamping position, whether empty or carrying the welded crossbeam 500, rotates to the loading / unloading station to await subsequent crossbeam 500 clamping operations. At this time, each welding robot 200 can weld the crossbeam 500 and mounting plate 510 at the first clamping position. During welding, the second rotating shaft 130 can rotate and adjust its angle as needed, and the welding angle of the welding torch can also be adjusted to cooperate in welding different parts. After the crossbeam 500 at the first clamping position is welded, the first rotating shaft 120 rotates, causing the second clamping position to rotate the unwelded crossbeam 500 to the welding station for subsequent welding. At this time, the welded crossbeam 500 at the first clamping position rotates to the loading / unloading station and is unloaded by a crane. Repeating the above steps allows for continuous production.

[0095] The welding method disclosed in this application embodiment is used to weld the mounting plate 510 to the crossbeam 500 using the aforementioned welding workstation. The welding torch of the welding robot 200 is equipped with a vision sensor, which collects the weld contour point cloud data of the crossbeam 500 and the mounting plate 510 in real time and transmits it to the control system 300. Specifically, the vision sensor can be positioned at the end of the welding torch of the welding robot 200, 20cm-50cm away from the tip of the welding wire. This positioning ensures that the vision sensor has a good field of view to collect the complete weld contour while avoiding damage to the vision sensor lens caused by welding spatter. The welding method specifically includes the following steps:

[0096] S10. Path planning and parameter setting: Using the structural model of the crossbeam 500 and mounting plate 510, the surface where the weld is located is unfolded and laid flat. A three-dimensional starting point, a three-dimensional ending point, and anti-collision points are set to generate the theoretically optimal welding path for the welding robot 200. The three-dimensional starting point is the initial theoretical coordinate position of the welding torch / wire tip when it begins the welding action in three-dimensional space. The three-dimensional ending point is the final theoretical coordinate position of the welding torch / wire tip when it completes the welding action and ends its trajectory in three-dimensional space. The anti-collision point is a specific critical spatial coordinate point where interference may occur between the welding robot 200 body or the welding torch during spatial movement. This theoretically optimal welding path planning not only considers the geometric distribution of the weld but also takes into account the safety of multiple welding robots 200 working collaboratively. When the welding robot 200 passes through the anti-collision point, the three-axis positioner 100 performs a stationary action or adjusts to a preset angle, with the optimization objective being to minimize the number of adjustments made by the three-axis positioner 100. By planning the welding path as described above, mechanical interference during the operation of the multi-welding robot 200 is effectively avoided, and the time loss caused by the frequent start-stop of the three-axis positioner 100 is minimized, thereby improving the production cycle time.

[0097] S20. Real-time welding and deviation correction: The welding robot 200 welds along the theoretically optimal welding path. The vision sensor scans the point cloud, and the control system 300 processes the data based on the point cloud scanned by the vision sensor, extracts the bevel features of the weld, and adjusts the welding process of the welding robot 200 in real time through the bevel features. Specifically, the bevel features may include bevel width, bevel depth, bevel centerline, and bevel side angles. Specifically, the bevel width refers to the lateral dimension at the opening of the weld surface, the bevel depth refers to the vertical distance from the bottom of the bevel to the surface, the bevel centerline refers to the trajectory line passing through the geometric center of the bevel cross-section, and the bevel side angles refer to the inclination angles of the two sides of the bevel relative to the welding surface of the crossbeam 500.

[0098] Compared to existing technologies, the welding method disclosed in this application achieves automatic welding of the crossbeam 500 and each mounting plate 510 through the aforementioned welding workstation, improving production efficiency and ensuring welding quality. Furthermore, this welding method achieves non-contact real-time perception of the weld contour through a vision sensor, and combines a theoretically optimal path including anti-collision points and a strategy for minimizing the number of adjustments by the three-axis positioner 100. This solves the problem of interference in operations of multiple welding robots 200 in confined spaces, significantly reducing the ineffective motion time of the three-axis positioner 100 and enabling high-precision real-time closed-loop control. Simultaneously, addressing the issue of slight deformation or bending of the crossbeam 500 due to insufficient machining accuracy, which can cause deviations when the welding robot 200 welds along a preset path, this application utilizes the real-time detection function of the vision sensor to compensate for the inability of relying solely on preset paths to adapt to workpiece errors, effectively solving the weld deviation problem and thus ensuring welding quality.

[0099] Taking a dual welding robot 200 as an example, due to the asymmetrical distribution of weld seams, the workload of the two welding robots 200 is often different. For example, one welding robot 200 needs to weld four weld seams, while the other welding robot 200 only needs to weld three weld seams. If, while one welding robot 200 is still working, the three-axis positioner 100 executes an instruction to adjust to a preset angle according to the progress of the other welding robot 200, the welding robot 200 that is currently working will be forced to interrupt welding due to the sudden change in the weld seam position, and may even collide with it. Therefore, in step S10, before the three-axis positioner 100 performs the action of adjusting to the preset angle, the control system 300 needs to determine whether there is a welding robot 200 currently in operation; if so, it waits for all welding robots 200 in operation to complete their current actions before the three-axis positioner 100 performs the action of adjusting to the preset angle. This resolves the potential conflicts that may arise from the asynchronous operation of multiple welding robots 200, prevents the welding stability of the welding robot 200 from being affected by the premature rotation of the three-axis positioner 100, and ensures the continuity and safety of the welding process.

[0100] In some embodiments disclosed in this application, step S20 involves real-time adjustment of the welding process based on the bevel features, specifically including the following steps:

[0101] S21. Welding torch height adjustment: The control system 300 determines whether there is a sudden change in the bevel width or bevel depth to confirm whether there is local deformation or splice seam on the surface of the crossbeam 500. If so, it further determines whether the number of sudden changes in a continuous time exceeds a preset threshold to further eliminate spatter or noise interference. If the number exceeds the preset threshold, it can be considered that there is a real geometric change on the surface of the crossbeam 500. At this time, the position of the tool center point of the welding torch along the welding torch axis is adjusted to compensate for the undulations of the surface of the crossbeam 500 and ensure that the wire extension length (i.e., the distance from the tip of the welding wire to the contact tip) is constant, thereby maintaining the stability of the welding arc.

[0102] S22. Weld tracking adjustment: To correct the path deviation caused by the overall bending of the crossbeam 500, the control system 300 calculates the weld tracking deviation in real time based on the distance between the bevel centerline and the theoretically optimal welding path. If the weld tracking deviation is greater than the deviation threshold, the control system 300 sends a signal to the welding robot 200 and corrects the two-dimensional position of the welding torch tool center point in the plane of the weld in real time to ensure that the welding wire is always aligned with the root of the bevel and to eliminate the position deviation caused by the thermal deformation or processing error of the crossbeam 500.

[0103] In actual production, there may be deviations in the assembly of the crossbeam 500 and the mounting plate 510, resulting in asymmetry on both sides of the bevel, i.e., one side has a larger angle and the other side has a smaller angle. If the welding torch is still kept at a vertical angle at this time, it may cause the weld to be biased to one side, resulting in incomplete fusion or undercut defects. Therefore, step S20 may also include the following steps:

[0104] S23. Welding torch angle adjustment: The control system 300 judges whether the angles on both sides of the bevel are symmetrical. If they are not symmetrical, the control system adjusts the welding torch to the side with the smaller angle to achieve adaptive adjustment of the welding posture, ensuring that the welding torch is in the optimal position of the molten pool for welding, and ensuring good fusion on both sides of the weld.

[0105] Since the crossbeam 500 is an ultra-long member, and the stress differences and impacts on the overall structural stability vary at different parts of the ultra-long member, different deviation thresholds can be set according to the specific location of the weld on the crossbeam 500. Specifically, taking the crossbeam 500 as an H-beam as an example, the crossbeam 500 includes interconnecting web plates and flanges. The weld connecting the mounting plate 510 to the web of the crossbeam 500 is the main load-bearing support part, and its welding quality directly determines whether the mounting plate 510 can be perpendicular to the two flanges. Therefore, the deviation threshold corresponding to this position is set to a smaller value. Conversely, the weld connecting to the flanges of the crossbeam 500 has a relatively weak impact on perpendicularity. Even if there is a slight deviation, it can still play a supporting role. Therefore, the deviation threshold corresponding to this position can be set to a larger value. That is, in step S22, different deviation thresholds are set according to the location of the weld on the crossbeam 500. The setting of the deviation thresholds includes the degree of influence of the weld quality at different locations on the structural stability of the crossbeam 500. For example, the allowable deviation threshold for the weld located at the web of the crossbeam 500 is less than the allowable deviation threshold for the weld located at the flange of the crossbeam 500, thereby achieving graded control. Under the premise of ensuring the welding quality of the key stress area, the ineffective adjustment action in the non-critical area is effectively reduced, and the welding efficiency and accuracy are balanced.

[0106] The terms "first" and "second," etc., used in the specification and claims of this application are used to distinguish different objects, not to describe a specific order, and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units may include steps or units not listed, but rather steps or units not listed. Additionally, in the description of embodiments in this application, "a plurality of" means two or more.

[0107] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Specific technical means in some embodiments may be incorporated, in whole or in part, into another embodiment unless explicitly excluded by another embodiment. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A welding workstation for welding mounting plates (510) onto a crossbeam (500), characterized in that, include: The three-axis positioner (100) has two clamping positions, which can alternate between the loading / unloading station and the welding station. Both clamping positions are provided with tooling fixtures (400) for clamping and fixing the crossbeam (500), and the position of the tooling fixtures (400) in the clamping positions is adjustable. At least two welding robots (200) are provided, each of which is movably disposed at the welding station along a first direction X and is used to weld the crossbeam (500) and the mounting plate (510) located at the welding station. The control system (300) is communicatively connected to the welding robot (200) and the three-axis positioner (100), and is used to control the alternating switching action of the two clamping positions and the welding action of the welding robot (200).

2. The welding workstation as described in claim 1, characterized in that, The tooling fixture (400) includes a first clamping assembly (410), a second clamping assembly (420), and a third clamping assembly (430). The first clamping assembly (410), the second clamping assembly (420), and the third clamping assembly (430) are all disposed at the clamping position. The first clamping assembly (410) is used to clamp and fix the crossbeam (500) along the first direction X. The second clamping assembly (420) is used to clamp and fix the crossbeam (500) along the second direction Y. The third clamping assembly (430) is used to clamp and fix the crossbeam (500) along the third direction Z. The first direction X, the second direction Y, and the third direction Z are arranged at an angle to each other. The crossbeam (500) is arranged at the clamping position along the first direction X. The clamping position is provided with an adjustment guide rail (101) extending along the first direction X, and a first adjustment slider (102) is slidably provided on the adjustment guide rail (101), and at least part of the first clamping assembly (410) is provided on the first adjustment slider (102).

3. The welding workstation as described in claim 2, characterized in that, The first clamping assembly (410) includes: At least two support rollers (411) are rotatably disposed at the clamping position, and each of the support rollers (411) is spaced apart along the first direction X, and the crossbeam (500) is disposed on the support rollers (411); A first positioning substrate (412) is disposed at the clamping position; The first clamping member (413) is disposed on the first adjusting slider (102). The first clamping member (413) and the first positioning base plate (412) are arranged opposite to each other along the first direction X and are used to clamp and fix the two ends of the crossbeam (500) along the first direction X.

4. The welding workstation as described in claim 3, characterized in that, The second adjusting slider (103) is slidably provided on the adjusting guide rail (101), and each of the support rollers (411) is slidably provided on the second adjusting slider (103). And / or, a third adjusting slider is slidably provided on the adjusting guide rail (101), and the first positioning base plate (412) is disposed on the third adjusting slider.

5. The welding workstation as described in claim 4, characterized in that, The second clamping assembly (420) includes a second positioning base plate (421) and a second clamping member (422) arranged opposite to each other along the second direction Y, and the second positioning base plate (421) and the second clamping member (422) are used to clamp and fix the crossbeam (500) on both sides along the second direction Y; There is at least one second clamping assembly (420) and it is disposed on the second adjusting slider (103).

6. The welding workstation as described in claim 4, characterized in that, The third clamping assembly (430) is at least one, and the third clamping assembly (430) includes a flipping avoidance drive (431) and a third clamping member (432). The flipping avoidance drive (431) is disposed on the second adjusting slider (103). The third clamping member (432) is rotatably disposed on the second adjusting slider (103) and connected to the power output end of the flipping avoidance drive (431). The flipping avoidance drive (431) is used to drive the third clamping member (432) to rotate so as to press the crossbeam (500) against the support roller (411), or to make the third clamping member (432) avoid the loading and unloading action of the crossbeam (500) in the clamping position.

7. The welding workstation as described in claim 4, characterized in that, The first adjusting slider (102) is provided with a first fastener (104), which is used to abut against the adjusting guide rail (101) for locking or insertion limiting. And / or, the second adjusting slider (103) is provided with a second fastener, which is used to abut against the adjusting guide rail (101) for locking or insertion limiting; And / or, the third adjusting slider is provided with a third fastener, which is used to abut against the adjusting guide rail (101) for locking or insertion limiting.

8. The welding workstation as described in claim 1, characterized in that, The triaxial positioner (100) includes: Base (110); A first rotating shaft (120) and a first driving mechanism, wherein the first rotating shaft (120) is rotatably mounted on the base (110) by the drive of the first driving mechanism, and the first rotating shaft (120) is connected to a displacement frame (121). The second rotating shaft (130) and the third rotating shaft (140) are rotatably disposed on opposite sides of the displacement frame (121), and the second rotating shaft (130) and the third rotating shaft (140) are respectively provided with a clamping position; The second drive mechanism and the third drive mechanism are used to drive the second rotating shaft (130) to rotate, and the third drive mechanism is used to drive the third rotating shaft (140) to rotate. The first rotating shaft (120), the second rotating shaft (130) and the third rotating shaft (140) all extend along the first direction X.

9. The welding workstation as described in claim 1, characterized in that, The welding robot (200) is equipped with a welding torch for welding the crossbeam (500) and the mounting plate (510). A vision sensor is provided on the side of the welding torch, and the acquisition end of the vision sensor faces the front of the welding torch. The vision sensor is communicatively connected to the control system (300) and is used to collect image data and guide the welding torch to track the weld seam of the crossbeam (500) and the mounting plate (510) in real time.

10. The welding workstation as described in claim 1, characterized in that, The welding workstation also includes a safety light curtain (600), a transmitting sensor, and a receiving sensor. The safety light curtain (600) is set around the perimeter of the welding station and has an entrance and exit. The transmitting sensor and the receiving sensor are set at the entrance and exit. The transmitting sensor is used to emit a detection beam to the receiving sensor. The receiving sensor is communicatively connected to the control system (300). If the receiving sensor does not receive the detection beam from the transmitting sensor, the control system (300) controls the welding robot (200) to stop moving.

11. A welding method, characterized in that, The welding robot (200) is used to weld the mounting plate (510) to the crossbeam (500) by means of a welding workstation as described in any one of claims 1-10. The welding gun of the welding robot (200) is equipped with a vision sensor, which is used to collect the weld contour point cloud data of the crossbeam (500) and the mounting plate (510) in real time and transmit it to the control system (300). include step: S10, Path planning and parameter setting: Using the structural models of the crossbeam (500) and the mounting plate (510), the surface where the weld is located is unfolded and laid out, and a three-dimensional starting point, a three-dimensional ending point and a collision avoidance point are set to generate the theoretical optimal welding path of the welding robot (200); When the welding robot (200) passes through the collision avoidance point, the three-axis positioner (100) performs a stationary action or adjusts to a preset angle, with the goal of minimizing the number of actions of the three-axis positioner (100); S20. Real-time welding and deviation correction: The welding robot (200) welds along the theoretically optimal welding path. The control system (300) extracts the bevel features of the weld seam based on the point cloud data scanned by the vision sensor, and adjusts the welding process of the welding robot (200) in real time through the bevel features. The bevel features include bevel width, bevel depth, bevel centerline and bevel angles on both sides.

12. The welding method as described in claim 11, characterized in that, In step S10, before the three-axis positioner (100) performs the action of adjusting to the preset angle, the control system (300) determines whether there is a welding robot (200) in working state. If present, the three-axis positioner (100) will wait for all the welding robots (200) in operation to complete their current actions before performing the action of adjusting to the preset angle.

13. The welding method as described in claim 11, characterized in that, In step S20, the real-time adjustment of the welding process of the welding robot (200) based on the bevel features specifically includes the following steps: S21. Welding torch height adjustment. The control system (300) determines whether the bevel width or bevel depth has changed abruptly. If so, it further determines whether the number of abrupt changes within a continuous time exceeds a preset threshold. If the number of times exceeds the preset threshold, the position of the tool center point of the welding gun along the axis of the welding gun is adjusted to ensure that the wire extension length is constant. S22. Weld tracking adjustment: The control system (300) calculates the weld tracking deviation in real time based on the distance between the center line of the groove and the theoretical optimal welding path. If the weld tracking deviation is greater than the deviation threshold, the control system (300) sends a signal to the welding robot (200) and corrects the two-dimensional position of the tool center point of the welding gun in the plane of the weld in real time to ensure that the welding wire is always aligned with the root of the groove.

14. The welding method as described in claim 13, characterized in that, Step S20 further includes: S23. Welding torch angle adjustment: The control system (300) determines whether the angles on both sides of the bevel are symmetrical. If they are not symmetrical, the control system adjusts the welding torch to the side with the smaller angle.

15. The welding method as described in claim 13, characterized in that, In step S22, different deviation thresholds are set according to the position of the weld on the crossbeam (500); The deviation threshold is set based on the degree of influence of the weld quality at different locations on the structural stability of the beam (500).

16. The welding method as described in claim 15, characterized in that, The crossbeam (500) includes interconnected web and flanges, and the allowable deviation threshold for the welds on the web is less than the allowable deviation threshold for the welds on the flanges.

Images