Pipe and pipe plate welding robot welding gun pulling prevention device and using method thereof

Abstract

The invention relates to an anti-pulling device for a welding gun of a pipe and pipe plate welding robot, which is applied to the welding gun, and the anti-pulling device connects an elastic sensor with a mandrel in the welding gun through a connecting part, so that mechanical deformation caused by pulling force can be directly sensed. Afterwards, the safety control module can detect a conduction signal of the elastic sensor and control the executing mechanism to enable the mechanical arm to execute the sudden stop action, meanwhile, an alarm is given out, and therefore the situation that the welding gun is damaged due to the too large pulling force is effectively avoided. The invention further provides a using method of the pipe and pipe plate welding robot welding gun pulling preventing device, the reliability and safety of welding operation can be remarkably improved, and the advantages are obvious.

Description

Technical Field

[0001] This invention relates to the field of tube and tube sheet welding robot technology, specifically to a tube and tube sheet welding robot welding torch anti-pulling device and its usage method. Background Technology

[0002] In tube-to-tube sheet welding operations, the automated operation of welding robots has become a key means to improve welding efficiency and quality. The standard operating procedure of existing tube-to-tube sheet welding robots is as follows: the robotic arm carries the welding torch to the position to be welded, inserts the welding torch into the tube hole to be welded, the mandrel inside the welding torch expands and tightens inside the tube hole, and then the robotic arm disengages from the welding torch and enters the next work cycle or a waiting state.

[0003] However, in actual working conditions, there are instances where the robotic arm begins to move before the disengagement action between the robotic arm and the welding torch is fully completed. This directly exerts a pulling force on the already tightened and fixed welding torch. This pulling force can not only cause the welding torch to shift position, resulting in welding defects or even welding failure, but may also damage key components inside the welding torch, such as the mandrel and tightening mechanism, increasing equipment maintenance costs and downtime, and threatening the safety of operators and the stable operation of the equipment.

[0004] Therefore, it is essential to propose a welding torch anti-pulling device and its usage method that can overcome the above problems.

[0005] It is understood that the above statements only provide background information related to the present invention and do not necessarily constitute prior art. Summary of the Invention

[0006] The purpose of this invention is to provide a device for preventing the welding torch from being pulled in a tube-to-tube sheet welding robot and its usage method, which is used to overcome the welding defects and equipment damage caused by the pulling of the welding torch in the prior art. It achieves real-time monitoring and rapid response through elastic sensors and safety control modules, thereby improving the reliability and safety of welding operations.

[0007] To achieve the above objectives, the present invention provides an anti-pull device for a welding torch of a tube-tube sheet welding robot, which is applied to the welding torch. The welding torch includes a welding torch body and a mandrel. The welding torch body is a hollow frame structure, which forms an internal accommodating space. A support is provided in the accommodating space and is connected to the welding torch body. One end of the mandrel is fixed to the support, and the other end extends out of the accommodating space as a welding torch fixing head, which is used to insert into the pipe hole to be welded and tighten it.

[0008] The anti-pull device includes: a connecting component, which is a sleeve-type structure, coaxially sleeved on one end of the mandrel located within the receiving space, and rigidly connected to the mandrel; an elastic sensor, disposed within the receiving space, including an electronic sensing structure and an elastic element interconnected, the electronic sensing structure being fixed to the welding torch body, and the elastic element contacting the connecting component to generate contact pressure; a safety control module, communicatively connected to the electronic sensing structure of the elastic sensor, used to detect in real time whether the electronic sensing structure emits a conduction state signal; and an actuator, communicatively connected to the safety control module, which controls the actuator to perform a protective action when the safety control module detects that the electronic sensing structure changes from continuously emitting a conduction state signal to not emitting a conduction state signal, indicating that it has changed from a conduction state to an open circuit state.

[0009] Preferably, the support and the welding torch body have a relative movement distance within a preset range, and the two can move relative to each other within this range.

[0010] Preferably, the connection between the electronic sensing structure and the elastic element is further provided with a normally closed elastic contact point structure; wherein, in the normal state of the welding torch, the elastic element is compressed and deformed, pressing the normally closed elastic contact point structure to keep it closed, at which time the electronic sensing structure is in a conductive state and continuously emits a conductive signal; when the robotic arm pulls on the welding torch body, causing the welding torch body to be subjected to a pulling force exceeding a preset threshold, a relative displacement occurs between the welding torch body and the connecting component, causing the contact pressure between the elastic element and the connecting component to decrease or disappear, the elastic element rebounds, the normally closed elastic contact point structure disconnects, the electronic sensing structure switches to an open circuit state and stops emitting a conductive signal.

[0011] Preferably, the relative displacement between the welding torch body and the connecting component is less than the relative movement distance between the bracket and the welding torch body; the relative displacement between the welding torch body and the connecting component is 2mm-5mm.

[0012] Preferably, the elastic sensor is a spring sensor, and the elastic element is a spring.

[0013] Preferably, the actuator is communicatively connected to the drive system of the robotic arm, and the actuator includes a robotic arm emergency stop module; the protection action is: the robotic arm emergency stop module sends a power cut-off command to the drive system of the robotic arm to cut off the drive power of the robotic arm, or sends an emergency stop command to the drive system of the robotic arm to control the robotic arm to perform an emergency stop action.

[0014] Preferably, the actuator further includes an audible and visual alarm, and the protection action further includes activating the audible and visual alarm to issue an audible and visual alarm.

[0015] Preferably, the robotic arm and the welding torch body are detachably connected via a quick-connect interface; the quick-connect interface is a snap-fit ​​aviation plug.

[0016] This invention also provides a method for using an anti-pull device for a welding torch in a pipe-to-tube sheet welding robot, which includes the following steps: S1. In the initial state, the robotic arm and the welding torch body are connected through a quick-connect interface. The robotic arm drives the welding torch to move to the target welding position where the pipe hole to be welded is located through the welding torch body. S2. Insert the mandrel of the welding torch into the hole of the pipe to be welded and tighten it to fix the mandrel to the hole of the pipe to be welded. Then the robotic arm performs the action of disengaging from the welding torch body. At this time, the elastic sensor is pressed into contact with the connecting part, the normally closed elastic contact point structure of the elastic sensor is closed, and the safety control module detects the continuous conduction status signal emitted by the elastic sensor, indicating that it is in the conduction state. S3. If the robotic arm moves before it is completely detached from the welding torch body and applies a pulling force to the welding torch body, when the pulling force exceeds a preset threshold, a relative displacement occurs between the elastic sensor and the connecting component. Consequently, the elastic element undergoes elastic deformation, causing the normally closed elastic contact point structure to break. At this time, the elastic sensor changes from a conducting state to an open circuit state, and no conducting state signal is output to the safety control module. The safety control module detects the signal change and determines that the robotic arm is pulling on the welding torch. S4. The safety control module controls the actuator to perform protective actions, causing the robotic arm to stop suddenly and activating an audible and visual alarm to notify the operator. S5. After the operator troubleshoots the problem, he manually resets the elastic sensor, causing the elastic element to re-engage with the connecting component and generate pressure, and the normally closed elastic contact point structure remains closed due to this pressure; the safety control module detects that the elastic sensor is in the conducting state again, controls the audible and visual alarm to deactivate the alarm, and allows the robotic arm to resume operation.

[0017] Preferably, in step S3, the reaction time of the elastic sensor from the conducting state to the open circuit state is 1ms-10ms.

[0018] In summary, compared with the prior art, the anti-pull device for the welding torch of a tube-tube sheet welding robot and its usage method provided by the present invention have at least the following beneficial effects: (1) The present invention uses an elastic sensor connected to the mandrel inside the welding torch through a connecting component, which can directly sense the mechanical deformation caused by the pulling force, effectively avoid positional displacement and component damage caused by the pulling force, and respond quickly and reliably. (2) The elastic sensor used in this invention has a simple structure and low manufacturing cost. It does not require a complex force sensing chip and signal amplification circuit, and is easy to integrate into the existing welding torch structure. (3) The present invention has dual protection of emergency stop of robotic arm and sound and light alarm, which not only prevents the continuous occurrence of pulling action, but also reminds the operator to deal with the fault in time, avoids safety hazards and secondary damage, and has reliable safety. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the connection structure between the welding torch and the robotic arm in this invention; Figure 2 This is a cross-sectional view of the inside of the welding torch in this invention; Figure 3 This is a schematic diagram of the connection structure between the elastic sensor and the spindle in this invention; Figure 4 This is a partial enlarged view of the elastic sensor in this invention; In the picture: 1-Welding torch, 11-Welding torch body, 12-Mandrel, 2-Robotic arm, 3-Elastic sensor, 31-Electronic sensing structure, 32-Elastic element, 4-Connecting component. Detailed Implementation

[0020] The following is in conjunction with the appendix Figure 1 To be continued Figure 4 The present invention will be further illustrated by describing a preferred embodiment in detail.

[0021] It should be noted that the accompanying drawings are in a very simplified form and use non-precise proportions. They are only used to facilitate and clarify the purpose of illustrating the embodiments of the present invention, and are not intended to limit the implementation conditions of the present invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationship, or adjustments to the size should still fall within the scope of the technical content disclosed in the present invention, provided that they do not affect the effects and objectives that the present invention can produce.

[0022] It should be noted that, in this invention, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only the expressly listed elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0023] like Figure 1 and Figure 2As shown, this invention provides an anti-pull device for the welding torch of a pipe and tube sheet welding robot. The anti-pull device is applied to a welding torch 1, which includes a welding torch body 11 and a mandrel 12. The welding torch body 11 is a hollow frame structure with an internal accommodating space. The welding torch body 11 is detachably connected to a robotic arm 2 and is driven by the robotic arm 2 to move to the target welding position. A bracket is also provided in the accommodating space, which is connected to the welding torch body 11, and a support member is provided on the bracket. One end of the mandrel 12 is fixed to the bracket through the support member, and the other end extends outside the accommodating space as a welding torch fixing head, which is used to insert into the pipe hole to be welded and tighten it so that the welding torch 1 is fixed relative to the pipe hole to be welded during welding.

[0024] The connection between the bracket and the welding torch body 11 is such that they have a relative movement distance within a preset range. That is, within this preset range, the bracket and the welding torch body 11 can move relative to each other. When the movement distance reaches the end of the preset range, the bracket and the welding torch body 11 remain relatively fixed. Since the mandrel 12 is fixedly mounted on the bracket, it can be understood that the mandrel 12 and the welding torch body 11 also have this relative movement distance.

[0025] It should be noted that during the preparation process before welding, the robotic arm 2 drives the welding torch 1 to move to the target welding position. At this time, the mandrel 12 moves together with the welding torch body 11. When the welding position is reached, the mandrel 12 is inserted into the pipe hole to be welded and tightened to fix it to the pipe hole. Before the actual welding operation, the robotic arm 2 needs to be detached from the welding torch 1 and moved away from the welding position. However, if the robotic arm 2 moves significantly before it is completely detached from the welding torch 1, it will apply a pulling force to the welding torch body 11. At this time, the mandrel 12 is fixed in the pipe hole to be welded and cannot move. When the pulling force exceeds a preset threshold, it will cause a certain relative displacement between the welding torch body 11 and the mandrel 12. However, it should be noted that the relative displacement at this time must be within the preset range of the aforementioned relative movement distance. If it exceeds this range, it indicates that the connection structure between the welding torch body 11 and the mandrel 12 has been damaged.

[0026] Furthermore, such as Figure 3 and Figure 4 As shown, the welding torch anti-pull device includes: The connecting component 4 is a sleeve-type structure, coaxially sleeved at one end of the mandrel 12 located within the receiving space, and rigidly connected to the mandrel 12 for transmitting pulling force; it can be understood that by rigidly connecting and coaxially positioning the connecting component 4 to the mandrel 12, and moving synchronously with the mandrel 12, it can ensure that the pulling force is transmitted without loss when the welding torch body 11 and the mandrel 12 are pulled. The elastic sensor 3 is disposed within the accommodating space and includes an electronic sensing structure 31 and an elastic element 32 connected to each other; wherein, the electronic sensing structure 31 is fixed on the welding torch body 11, and the elastic element 32 contacts the connecting component 4 to generate contact pressure.

[0027] Furthermore, a normally closed elastic contact point structure (not shown in the figure) is also provided at the connection between the electronic sensing structure 31 and the elastic element 32. When the welding torch 1 is in normal condition, the elastic element 32 contacts the connecting component 4 and generates contact pressure, causing the elastic element 32 to deform due to the pressure, thereby pressing the normally closed elastic contact point structure, so that the normally closed elastic contact point structure remains closed due to external pressure, the elastic sensor 3 is in the conducting state, and the electronic sensing structure 31 continuously emits a conducting state signal.

[0028] When the robotic arm 2 moves before it is completely disengaged from the welding torch 1, and the robotic arm 2 pulls on the welding torch body 11, causing the welding torch body 11 to be subjected to a pulling force exceeding a preset threshold, since the mandrel 12 is already taut in the hole to be welded and cannot move, a relative displacement will occur between the welding torch body 11 and the connecting component 4. This relative displacement will cause the contact pressure between the elastic element 32 and the connecting component 4 to decrease or disappear. The elastic element 32 will undergo a rebound deformation, and thus it will be unable to press the normally closed elastic contact point structure. As a result, the normally closed elastic contact point structure will be disconnected, the elastic sensor 3 will switch from the conducting state to the open circuit state, and the electronic sensing structure 31 will no longer emit a conducting state signal.

[0029] It is worth noting that, in actual situations, the relative displacement is a very small value, and the relative displacement is less than the relative movement distance between the bracket and the welding torch body 11, so as to prevent the welding torch 1 from being damaged by the pulling of the robotic arm 2. In a preferred embodiment of the present invention, the relative displacement is 2mm-5mm.

[0030] In a preferred embodiment of the present invention, the elastic sensor 3 is preferably a spring sensor, and the elastic element 32 is preferably a spring.

[0031] Furthermore, the welding torch anti-pulling device also includes: The safety control module (not shown in the figure) is communicatively connected to the electronic sensing structure 31 of the elastic sensor 3, and is used to detect in real time whether the electronic sensing structure 31 sends a conduction status signal; The actuator (not shown in the figure) is communicatively connected to the safety control module. When the safety control module detects that the electronic sensing structure 31 changes from continuously emitting a conducting state signal to not emitting a conducting state signal, indicating that it has changed from a conducting state to an open circuit state, it controls the actuator to perform a protection action.

[0032] Furthermore, the actuator is also communicatively connected to the drive system of the robotic arm 2; and the actuator includes a robotic arm emergency stop module, wherein the protection action is that the robotic arm emergency stop module sends a power cut-off command to the drive system of the robotic arm 2 to cut off the drive power of the robotic arm 2, or sends an emergency stop command to the drive system of the robotic arm to control the robotic arm 2 to perform an emergency stop action.

[0033] Furthermore, the actuator also includes an audible and visual alarm, and the protective action further includes activating the audible and visual alarm to issue an audible and visual alarm.

[0034] Furthermore, in a preferred embodiment of the present invention, the robotic arm 2 and the welding torch body 11 are detachably connected via a quick-connect interface, and the quick-connect interface is preferably a snap-fit ​​aviation plug to improve convenience and stability.

[0035] The present invention also provides a method for using an anti-pulling device for the welding torch of a pipe-tube sheet welding robot, comprising the following steps: S1. In the initial state, the robotic arm 2 is connected to the welding torch body 11 through a quick-connect interface. The robotic arm 2 drives the welding torch 1 to move to the target welding position where the pipe hole to be welded is located through the welding torch body 11. S2. Insert the mandrel 12 of the welding torch 1 into the pipe hole to be welded and tighten it to fix the mandrel 12 to the pipe hole to be welded. Then the robotic arm 2 performs the action of disengaging from the welding torch body 11 of the welding torch 1. At this time, the elastic sensor 3 is pressed into contact with the connecting part 4, the normally closed elastic contact point structure of the elastic sensor 3 is closed, and the safety control module detects the continuous conduction state signal emitted by the elastic sensor 3, indicating that it is in the conduction state. S3. If the robotic arm 2 moves before completely disengaging from the welding torch body 11 and applies a pulling force to the welding torch body 11, when the pulling force exceeds a preset threshold, a relative displacement occurs between the elastic sensor 3 and the connecting component 4. Consequently, the elastic element 32 undergoes elastic deformation, causing the normally closed elastic contact point structure to break. At this time, the elastic sensor 3 changes from a conducting state to an open circuit state, and no conducting state signal is output to the safety control module. The safety control module detects the signal change and determines that the robotic arm 2 is pulling on the welding torch 1. S4. The safety control module controls the actuator to perform a protective action, causing the robotic arm 2 to stop suddenly and activating an audible and visual alarm to notify the operator. S5. After the operator troubleshoots the problem, he manually resets the elastic sensor 3, so that the elastic element 32 re-contacts the connecting component 4 and generates pressure, and the normally closed elastic contact point structure remains closed due to the pressure; the safety control module detects that the elastic sensor 3 is in the conducting state again, controls the audible and visual alarm to deactivate the audible and visual alarm, and allows the robotic arm 2 to resume operation.

[0036] Furthermore, in step S3, the reaction time of the elastic sensor 3 from the conducting state to the open circuit state is 1ms-10ms.

[0037] It is understandable that, in practical applications, the function of this invention is that when the welding torch 1 is subjected to a pulling force exceeding the safety threshold due to the erroneous operation of the robotic arm 2, the welding torch anti-pulling device can convert it into an emergency stop signal for the robotic arm and issue an alarm within milliseconds, thereby effectively limiting the relative displacement of each component of the welding torch 1 within the safe range of elastic deformation, fundamentally avoiding structural damage to the welding torch 1 caused by rigid pulling.

[0038] In summary, the present invention provides an anti-pull device for a welding torch of a pipe and tube sheet welding robot and its usage method. First, it uses an elastic sensor connected to the mandrel inside the welding torch via a connecting component, which can directly sense the mechanical deformation caused by the pulling force, with a rapid and reliable response, effectively preventing positional displacement and component damage caused by the pulling force. Second, it has dual protection with both emergency stop of the robotic arm and audible and visual alarms, which not only prevents the continuous occurrence of pulling action, but also promptly reminds the operator to handle the fault, avoiding safety hazards and secondary damage, with extremely high safety performance. Third, the elastic sensor has a simple structure and low manufacturing cost, requiring no complex force sensing chip and signal amplification circuit, making it easy to integrate into the existing welding torch structure.

[0039] Although the present invention has been described in detail through the preferred embodiments above, it should be understood that the above description should not be considered as a limitation of the present invention. Various modifications and substitutions to the present invention will be apparent to those skilled in the art after reading the above description. Therefore, the scope of protection of the present invention should be defined by the appended claims.

Claims

1. A device for preventing pulling on a welding torch in a tube-to-tube sheet welding robot, applied to a welding torch, the welding torch comprising a torch body and a mandrel, characterized in that, The welding torch body is a hollow frame structure, forming an internal receiving space; a bracket is provided in the receiving space, which is connected to the welding torch body; one end of the mandrel is fixed to the bracket, and the other end extends out of the receiving space as a welding torch fixing head, which is used to insert into the pipe hole to be welded and tighten it; The anti-pull device includes: The connecting component is a sleeve-type structure, coaxially sleeved at one end of the mandrel located within the receiving space, and rigidly connected to the mandrel; An elastic sensor, disposed within the receiving space, includes an interconnected electronic sensing structure and an elastic element. The electronic sensing structure is fixed to the welding torch body, and the elastic element contacts the connecting component to generate contact pressure. The safety control module is communicatively connected to the electronic sensing structure of the elastic sensor and is used to detect in real time whether the electronic sensing structure emits a conduction status signal. The actuator is communicatively connected to the safety control module. When the safety control module detects that the electronic sensing structure changes from continuously emitting a conducting state signal to not emitting a conducting state signal, indicating that it has changed from a conducting state to an open circuit state, the actuator is controlled to perform a protection action.

2. The welding torch anti-pulling device as described in claim 1, characterized in that, The bracket and the welding torch body have a relative movement distance within a preset range, and the two can move relative to each other within this range.

3. The welding torch anti-pulling device as described in claim 2, characterized in that, The connection between the electronic sensing structure and the elastic element is also provided with a normally closed elastic contact point structure. In the normal state of the welding torch, the elastic element is deformed under pressure and presses the normally closed elastic contact point structure to keep it closed. At this time, the electronic sensing structure is in the conducting state and continuously sends out a conducting signal. When the robotic arm pulls on the welding torch body, causing the welding torch body to be subjected to a pulling force exceeding a preset threshold, a relative displacement occurs between the welding torch body and the connecting component, reducing or eliminating the contact pressure between the elastic element and the connecting component. The elastic element rebounds, the normally closed elastic contact point structure breaks, and the electronic sensing structure switches to an open circuit state and stops emitting conduction signals.

4. The welding torch anti-pulling device as described in claim 3, characterized in that, The relative displacement between the welding torch body and the connecting component is less than the relative movement distance between the bracket and the welding torch body; The relative displacement between the welding torch body and the connecting component is 2mm-5mm.

5. The welding torch anti-pulling device as described in claim 1, characterized in that, The elastic sensor is a spring sensor, and the elastic element is a spring.

6. The welding torch anti-pulling device as described in claim 1, characterized in that, The actuator is communicatively connected to the drive system of the robotic arm, and the actuator includes a robotic arm emergency stop module; The protection action is as follows: the robotic arm emergency stop module sends a power cut-off command to the robotic arm's drive system to cut off the robotic arm's drive power, or sends an emergency stop command to the robotic arm's drive system to control the robotic arm to perform an emergency stop action.

7. The welding torch anti-pulling device as described in claim 1, characterized in that, The actuator also includes an audible and visual alarm, and the protective action further includes activating the audible and visual alarm to issue an audible and visual alarm.

8. The welding torch anti-pulling device as described in claim 1, characterized in that, The robotic arm and the welding torch body are detachably connected via a quick-connect interface; The quick-connect interface is a snap-on aviation plug.

9. A method for using a welding torch anti-pull device for a pipe-tube sheet welding robot, implemented using the welding torch anti-pull device as described in any one of claims 1-8, comprising the following steps: S1. In the initial state, the robotic arm and the welding torch body are connected through a quick-connect interface. The robotic arm drives the welding torch to move to the target welding position where the pipe hole to be welded is located through the welding torch body. S2. Insert the mandrel of the welding torch into the hole of the pipe to be welded and tighten it to fix the mandrel to the hole of the pipe to be welded. Then the robotic arm performs the action of disengaging from the welding torch body. At this time, the elastic sensor is pressed into contact with the connecting component, the normally closed elastic contact point structure of the elastic sensor is closed, and the safety control module detects the continuous conduction status signal emitted by the elastic sensor, indicating that it is in the conduction state. S3. If the robotic arm moves before it is completely detached from the welding torch body and applies a pulling force to the welding torch body, when the pulling force exceeds the preset threshold, a relative displacement occurs between the elastic sensor and the connecting component, and the elastic element undergoes elastic deformation, causing the normally closed elastic contact point structure to break. At this time, the elastic sensor changes from the conducting state to the open circuit state, and no conducting state signal is output to the safety control module. The safety control module detected a signal change and determined that the robotic arm was pulling on the welding torch. S4. The safety control module controls the actuator to perform protective actions, causing the robotic arm to stop suddenly and activating an audible and visual alarm to notify the operator. S5. After the operator troubleshoots the problem, he manually resets the elastic sensor, causing the elastic element to re-engage with the connecting component and generate pressure, and the normally closed elastic contact point structure remains closed due to this pressure; the safety control module detects that the elastic sensor is in the conducting state again, controls the audible and visual alarm to deactivate the alarm, and allows the robotic arm to resume operation.

10. The method of using the welding torch anti-pulling device as described in claim 9, characterized in that, In step S3, the reaction time of the elastic sensor from the conducting state to the open circuit state is 1ms-10ms.

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