Self-adaptive flexible rolled plate welding processing system and processing method

Abstract

The invention discloses a self-adaptive flexible rolled plate welding machining system and method. The self-adaptive flexible rolled plate welding machining system comprises a control system, a self-adaptive flexible rolled plate system and an automatic welding system. The self-adaptive flexible plate rolling system comprises a pre-machining platform and a plate rolling forming system, the pre-machining platform provides a forming platform for plate rolling forming and conveys pre-machined parts to the plate rolling forming system, the plate rolling forming system comprises a core shaft, a self-adaptive bottom shape control mechanism and a top pressing mechanism, the core shaft is matched with the parts to be formed, and the self-adaptive bottom shape control mechanism is matched with the top pressing mechanism. The self-adaptive bottom shape control mechanism is used for forming a pre-machined part into a U-shaped part, and the top pressing mechanism is used for pressing the upper end of the U-shaped part to the mandrel. The mandrel is adopted as the basis of plate rolling forming, a part is firstly formed into a U-shaped part through the self-adaptive bottom shape control mechanism, then the upper portion of the U-shaped part is pressed and formed through the top pressing mechanism, plate rolling forming of the part is achieved, the forming efficiency of the tubular part is improved, and the automation degree of machining is greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of plate forming technology, specifically relating to an adaptive flexible plate welding system and processing method. Background Technology

[0002] Currently, large-diameter aluminum alloy conduit parts are usually produced by rolling and welding sheet metal. Both rolling and welding are done manually, and the two processes are completed independently on different equipment. This results in low processing efficiency, high skill requirements for operators, and long processing cycles, making it difficult to meet the needs of intelligent and digital manufacturing. Summary of the Invention

[0003] The purpose of this invention is to provide an adaptive flexible coil welding system and method to solve the problems of low forming efficiency, high skill requirements and long production cycle of existing processing methods.

[0004] This invention is achieved through the following technical solution: An adaptive flexible coil welding system includes a control system, an adaptive flexible coil system, and an automatic welding system. The control system is used to generate control commands based on the information of the pre-processed parts to control the adaptive flexible roll plate system and the automatic welding system; The adaptive flexible roll forming system includes a pre-processing platform and a roll forming system. The pre-processing platform provides a forming platform for roll forming and sends the pre-processed parts to the roll forming system. The roll forming system includes a mandrel, an adaptive bottom shaping mechanism, and a top pressing mechanism. The mandrel is matched with the part to be formed. The adaptive bottom shaping mechanism is used to form the pre-processed part into a U-shaped part. The top pressing mechanism is used to press the upper end of the U-shaped part onto the mandrel. The automatic welding system is used to weld the seams of formed parts that are rolled on a mandrel.

[0005] In some embodiments of the present invention, the top of the mandrel is configured as a plane, and an axially oriented weld groove is formed at the center of the top plane.

[0006] In some embodiments of the present invention, the pre-processing platform includes a processing platform and a feeding mechanism, wherein the feeding mechanism and the processing platform are slidably connected by a feeding guide rail, and the feeding mechanism is used to feed the pre-processed parts to the coil forming system.

[0007] In some embodiments of the present invention, the adaptive bottom shaping mechanism includes a side top clamping mechanism, a support platform, a lifting mechanism, and a flexible connecting mechanism. The side top clamping mechanism includes two opposing top clamping plates and a top clamping drive member capable of driving the top clamping plates to open and close relative to each other. The two top clamping plates are respectively disposed on both sides of the support platform and are respectively connected by the flexible connecting mechanism. The lifting mechanism is used for lifting and adjusting the support platform.

[0008] In some embodiments of the present invention, the top pressing mechanism includes a support disposed opposite to each other, a pressing drive member disposed on the support, and a top pressing block disposed on the pressing drive member. The pressing drive member is used to drive the top pressing block to move horizontally, and the position of the top pressing block is adapted to the height of the top plane of the mandrel.

[0009] In some embodiments of the present invention, the plate forming system further includes an automatic correction mechanism for correcting the seam gap at the top of the plate forming part.

[0010] In some embodiments of the present invention, the automatic correction mechanism includes an extrusion bracket and an extrusion roller disposed on the extrusion bracket. The extrusion bracket includes a fixed bracket and a support bracket, which are disposed opposite to each other. The extrusion roller is disposed at the free end of the fixed bracket and is rotatably connected to the fixed bracket. The support bracket cooperates with the weld groove.

[0011] In some embodiments of the present invention, a visual inspection system is provided on the extrusion bracket at the front end of the extrusion roller, and the visual inspection system is used to identify and detect the quality of the seam.

[0012] On the other hand, the present invention also provides an adaptive flexible coil welding processing method, which uses an adaptive flexible coil welding processing system to perform coil welding forming operations, including the following steps: The control system selects the type of part, calls the processing parameters from the database, and generates control commands. The control system sends control commands to the adaptive flexible roll plate system, loading the mandrel and the adaptive bottom shaping mechanism; Send the pre-processed parts to the processing area; The adaptive bottom shaping mechanism controls the pre-processed part to form a U-shaped part, and then the top pressing mechanism presses the upper end of the U-shaped part onto the mandrel to complete the plate rolling and obtain a cylindrical part. Control the automatic welding system to perform welding operations and complete the welding and forming of the rolled plate.

[0013] In some embodiments of the present invention, after the coil is formed, the automatic correction mechanism is controlled to reciprocate along the weld groove on the mandrel to squeeze and correct the gap between the formed parts. The gap image is collected by a vision inspection system, and the correction quality is detected at the same time as the correction until the gap between the parts meets the welding requirements.

[0014] Compared with the prior art, the present invention has the following advantages and beneficial effects: This invention uses a mandrel as the basis for plate rolling. The part is first formed into a U-shape by an adaptive bottom shaping mechanism, and then the upper part of the U-shape is pressed and shaped by a top pressing mechanism to achieve plate rolling. The adaptive bottom shaping mechanism can adaptively adjust according to the diameter of the mandrel to ensure the quality and accuracy of plate rolling.

[0015] This invention enables automatic rolling, automatic correction, and automatic welding of parts, improving the forming efficiency of tubular parts and greatly enhancing the degree of automation in the processing. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the adaptive flexible coil welding system according to an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the roll forming system in an embodiment of the present invention.

[0019] Figure 3 This is a schematic diagram of the adaptive bottom shaping mechanism in an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the structure of the pre-processed parts being sent to the processing platform in an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the forming process using an adaptive bottom shaping mechanism in an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the state of forming a U-shaped part using an adaptive bottom shaping mechanism in an embodiment of the present invention.

[0023] Figure 7 This is a schematic diagram of the automatic correction mechanism in an embodiment of the present invention.

[0024] Figure 8 This is a schematic diagram of the control process for the welding of rolled plates according to an embodiment of the present invention.

[0025] in: 1. Control system; 2. Adaptive flexible roll plate system; 3. Automatic welding system; 4. Pre-processed parts; 5. U-shaped parts; 2-1. Processing platform; 2-2. Feeding mechanism; 2-3. Reference platform; 2-4. Feeding guide rail; 2-5. Support; 2-6. Pressing drive component; 2-7. Top pressure block; 2-8. Top clamping plate; 2-9. Support platform; 2-10. Flexible connection mechanism; 2-11. Mandrel; 2-11. Welding groove; 2-12. Fixed bracket; 2-13. Support bracket; 2-14. Extrusion roller; 2-15. Vision inspection system. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments.

[0027] Reference Figure 1 In some embodiments of the present invention, the adaptive flexible roll plate welding processing system includes a control system 1, an adaptive flexible roll plate system 2, and an automatic welding system 3.

[0028] The control system includes a plate forming control program, a welding control program, and a corresponding process data parameter library. By setting the material type, pre-processed part specifications, and quantity, the control parameters for plate forming and automatic welding are determined.

[0029] The adaptive flexible roll system 2 includes a pre-processing platform and a roll forming system.

[0030] like Figure 2 The pre-processing platform includes a processing platform 2-1, a feeding mechanism 2-2, and a feeding guide rail 2-4. A reference platform 2-3 for positioning the pre-processed parts is provided at one end of the feeding mechanism 2-2. The feeding mechanism 2-2 is slidably connected to the processing platform 2-1 through the feeding guide rail 2-4, so that the feeding mechanism can send the pre-processed parts 4 to the roll forming system.

[0031] The coil forming system includes a mandrel 2-11, an adaptive bottom shaping mechanism, a top clamping mechanism, and an automatic correction mechanism.

[0032] The mandrel 2-11 is a columnar structure that matches the size of the conduit parts. Its top is set as a plane, and a weld groove 2-111 is opened in the center of the top plane along the axial direction, and a protective gas vent is provided.

[0033] like Figure 3 An adaptive bottom shaping mechanism is set on the processing platform, including a side top clamping mechanism, a support platform 2-9, a lifting mechanism, and a flexible connection mechanism 2-10.

[0034] The side clamping mechanism includes two opposing clamping plates 2-8 and a clamping drive component capable of driving the clamping plates to open and close relative to each other. After the control system 1 sets the part parameters, the clamping drive component in the support platform 2-9 will drive the clamping plates 2-8 to move to a position that matches the part specifications and fix them in place.

[0035] The upper end of the top clamping plate 2-8 facing the mandrel is set with a rounded chamfer to avoid damage to the surface of the part when clamping the pre-processed part through the top clamping plate.

[0036] Two top clamping plates 2-8 are respectively set on both sides of the support platform 2-9 and connected by a flexible connection mechanism. During the plate rolling forming operation, the top clamping drive drives the two top clamping plates to move toward the mandrel set between them until the distance between them reaches the same as the diameter of the part. At the same time, the lifting mechanism controls the lifting movement of the support platform so that the support platform moves to the pressing position at the bottom of the mandrel.

[0037] The flexible connecting mechanism 2-10 is connected at one end to the top clamping plate 2-8 and at the other end to the support platform 2-9. This allows the top clamping plate 2-8 to adjust its spacing according to the specifications of the parts, matching the plate rolling process for smoother plate rolling. It is also connected to the support platform 2-9 for lifting and lowering movement. The processing platform 2-1 has a space in the middle for setting up the support platform 2-9, which is moved by a lifting mechanism. The lifting mechanism is located at the bottom of the support platform 2-9 and is electrically driven to move the support platform 2-9 according to the plate rolling process flow set in the control system 1.

[0038] like Figure 4 , Figure 5 and Figure 6 The plate is bent and shaped into a U-shape by the clamping action of the side clamping mechanism.

[0039] The part is placed on the feeding mechanism 2-2, with its bottom aligned with the reference platform 2-3. The feeding mechanism 2-2 then delivers the part to the processing area via the feeding guide rail 2-4. When the pre-processed part 4 is fed to the coil forming system via the feeding mechanism 2-2, it is positioned between the mandrel 2-7 and the side clamping mechanism. The mandrel 2-7 presses down on the pre-processed part from above, and the side clamping mechanism moves upward. The top clamping plate 2-8 first contacts the pre-processed part, causing both ends of the pre-processed part to move upward around the mandrel 2-7, forming the pre-processed part into a U-shaped part. After the U-shaped part is formed, it completely separates from the feeding mechanism 2-2, and the feeding mechanism 2-2 returns to the processing platform.

[0040] To enable the sheet metal to be better formed at the bottom, the side of the top clamp plate 2-8 facing the mandrel is set as an arc-shaped surface that mates with the mandrel.

[0041] The top pressing mechanism is located outside the adaptive bottom shaping mechanism. After the adaptive bottom shaping mechanism shapes the sheet into a U-shaped part 5, the top pressing mechanism pushes and squeezes the two upper ends of the U-shaped part relative to each other, so that the upper end of the U-shaped part can be wound around the mandrel to form a cylindrical shape.

[0042] The top clamping mechanism includes a support 2-5 arranged opposite to each other, a clamping drive 2-6 respectively arranged on the support, and a top clamping block 2-7 arranged on the clamping drive. The clamping drive is used to drive the top clamping block to move horizontally. The position of the top clamping block is adapted to the height of the top plane of the mandrel, and the upper end of the U-shaped part is rolled into shape.

[0043] Similarly, the top pressure block 2-7 facing the mandrel can be set as an arc surface that mates with the mandrel, so that the upper end of the U-shaped part can be better pressed onto the mandrel, ensuring the quality of the rolled plate forming.

[0044] An automatic correction mechanism is used to correct the seam gap at the top of the rolled sheet forming part. It includes an extrusion bracket and extrusion rollers 2-14 mounted on the extrusion bracket. The extrusion bracket presses the extrusion rollers against the seam gap to correct it. By driving the extrusion rollers to reciprocate along the seam gap, the correction operation at the seam position is achieved to ensure the seam gap during welding.

[0045] like Figure 7 The extrusion bracket adopts a U-shaped bracket structure, including a fixed bracket 2-12 and a support bracket 2-13. The fixed bracket 2-12 and the support bracket 2-13 are arranged opposite to each other. The extrusion roller 2-14 is located at the free end of the fixed bracket and is rotatably connected to the fixed bracket. The support bracket 2-13 cooperates with the weld groove, which not only realizes the cooperation connection between the extrusion bracket and the mandrel, but also provides support for the extrusion action of the seam.

[0046] A vision inspection system 2-15 is installed on the front end of the extrusion roller on the extrusion bracket to identify and inspect the quality of the seam.

[0047] The automated welding system consists of a welding robotic arm and an intelligent control system for welding seams. Once the alignment is complete, the automated welding system is controlled to perform the welding operation.

[0048] This invention enables automatic rolling, automatic correction, and automatic welding of parts, improving the forming efficiency of tubular parts and greatly enhancing the degree of automation in the processing.

[0049] Using a mandrel as the basis for plate rolling, the part is first formed into a U-shape by an adaptive bottom shaping mechanism, and then the upper part of the U-shape is pressed and formed by a top clamping mechanism to achieve plate rolling. The adaptive bottom shaping mechanism can adaptively adjust according to the diameter of the mandrel to ensure the quality and accuracy of plate rolling.

[0050] Integrating the plate forming system with an automatic welding system, after the part is formed by plate rolling, the mandrel is used as a welding platform to perform welding operations on the formed part in the formed state, which can well ensure the quality of plate rolling welding.

[0051] After the sheet metal is formed, a correction operation is performed to ensure the accuracy of the weld seam gap. The correction quality of the weld seam is identified and detected between welds, realizing a closed-loop correction operation and ensuring the quality of the weld.

[0052] like Figure 1 In the adaptive flexible coil welding system, the control system can select corresponding part parameters on the control panel and export the corresponding processing parameters from the database, including: part size (diameter), quantity (pieces), and welding parameters. Administrators can also add parts and set parameters. By setting basic part information, the control system can directly access the processing parameters from the database.

[0053] Reference Figure 8 The processing flow of the processing method of the present invention is as follows: The control system selects the type of part, calls the processing parameters from the database, and generates control commands. The control system sends control commands to the adaptive flexible roll plate system, loading the mandrel and the adaptive bottom shaping mechanism; Once loading is complete, the pre-processed parts are sent to the processing area via the feeding mechanism on the processing platform; The plate rolling forming operation begins. The lifting mechanism of the adaptive bottom shaping mechanism is controlled to move upward, and the plate will be gradually formed into a U-shaped part. Then, the top pressure block of the top pressing mechanism moves laterally to complete the final plate rolling forming and obtain a cylindrical part. The automatic correction mechanism is controlled to reciprocate along the weld groove from the initial position to compress and correct the gap between the formed parts. The gap image is acquired by the vision inspection system, and the correction quality is detected at the same time until the gap meets the welding requirements. Control the automatic welding system to perform welding operations and complete the welding and forming of the rolled plate.

[0054] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., used to indicate the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of this invention is usually placed in during use. They are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0055] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this invention does not imply that the components are required to be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0056] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention in light of the specific circumstances.

[0057] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An adaptive flexible rolled plate welding system, characterized in that, This includes a control system, an adaptive flexible roll plate system, and an automated welding system; The control system is used to generate control commands based on the information of the pre-processed parts to control the adaptive flexible roll plate system and the automatic welding system; The adaptive flexible roll forming system includes a pre-processing platform and a roll forming system. The pre-processing platform provides a forming platform for roll forming and sends the pre-processed parts to the roll forming system. The roll forming system includes a mandrel, an adaptive bottom shaping mechanism, and a top pressing mechanism. The mandrel is matched with the part to be formed. The adaptive bottom shaping mechanism is used to form the pre-processed part into a U-shaped part. The top pressing mechanism is used to press the upper end of the U-shaped part onto the mandrel. The automatic welding system is used to weld the seams of formed parts that are rolled on a mandrel.

2. The adaptive flexible coil welding system according to claim 1, characterized in that, The top of the mandrel is set as a plane, and a weld groove is formed in the center of the top plane along the axial direction.

3. The adaptive flexible coil welding system according to claim 1, characterized in that, The pre-processing platform includes a processing platform and a feeding mechanism. The feeding mechanism and the processing platform are connected by a sliding fit through a feeding guide rail, and are used to send the pre-processed parts to the coil forming system.

4. The adaptive flexible coil welding system according to claim 1, characterized in that, The adaptive bottom control mechanism includes a side top clamping mechanism, a support platform, a lifting mechanism, and a flexible connection mechanism. The side top clamping mechanism includes two opposing top clamping plates and a top clamping drive component capable of driving the top clamping plates to open and close relative to each other. The two top clamping plates are respectively arranged on both sides of the support platform and are respectively connected by the flexible connection mechanism. The lifting mechanism is used for the lifting and adjusting of the support platform.

5. The adaptive flexible coil welding system according to claim 2, characterized in that, The top pressing mechanism includes a support arranged opposite to each other, a pressing drive member respectively arranged on the support, and a top pressing block arranged on the pressing drive member. The pressing drive member is used to drive the top pressing block to move horizontally, and the position of the top pressing block is adapted to the height of the top plane of the mandrel.

6. The adaptive flexible coil welding system according to claim 2, characterized in that, The plate forming system also includes an automatic correction mechanism for correcting the seam gap at the top of the plate forming part.

7. The adaptive flexible coil welding system according to claim 6, characterized in that, The automatic correction mechanism includes an extrusion bracket and extrusion rollers mounted on the extrusion bracket. The extrusion bracket includes a fixed bracket and a support bracket, which are arranged opposite to each other. The extrusion rollers are mounted on the free end of the fixed bracket and are rotatably connected to the fixed bracket. The support bracket cooperates with the weld groove.

8. The adaptive flexible coil welding system according to claim 6, characterized in that, A vision inspection system is installed on the front end of the extrusion roller on the extrusion bracket. The vision inspection system is used to identify and detect the quality of the seam.

9. An adaptive flexible rolled plate welding processing method, characterized in that, The adaptive flexible coil welding processing system according to any one of claims 1-8 is used for coil welding forming operations, comprising the following steps: The control system selects the type of part, calls the processing parameters from the database, and generates control commands. The control system sends control commands to the adaptive flexible roll plate system, loading the mandrel and the adaptive bottom shaping mechanism; Send the pre-processed parts to the processing area; The adaptive bottom shaping mechanism controls the pre-processed part to form a U-shaped part, and then the top pressing mechanism presses the upper end of the U-shaped part onto the mandrel to complete the plate rolling and obtain a cylindrical part. Control the automatic welding system to perform welding operations and complete the welding and forming of the rolled plate.

10. The adaptive flexible rolled plate welding method according to claim 9, characterized in that, After the coil is formed, the automatic correction mechanism is controlled to reciprocate along the weld groove on the mandrel to compress and correct the gap between the formed parts. The gap image is collected by the vision inspection system, and the correction quality is detected at the same time until the gap between the parts meets the welding requirements.

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