Intelligent welding device for electric power iron tower structure assembly and control method

Abstract

The invention belongs to the field of welding devices, and particularly relates to an intelligent welding device for an electric iron tower structural component, which comprises a welding manipulator and a welding tool, the welding tool comprises a base and a plurality of groups of supporting devices arranged on the base, each supporting device comprises a mounting frame, and a rotating disc is arranged on the side wall of each mounting frame; the rotating disc can rotate relative to the mounting frame, a through avoiding hole is formed in the mounting frame, a clamping groove is formed in the rotating disc, and the pole excess material penetrates through the clamping groove and the avoiding hole of the multiple supporting devices and is supported below the welding manipulator. The invention further comprises a control method of the welding device. During welding, through rotation of the rotating disc, welding seams on the front face and the back face of the tower pole excess material are welded, the thick tower pole excess material can be fully welded, manual participation is not needed in the rotating process in the welding process, the working efficiency is improved, and the labor intensity of workers is reduced.

Description

Technical Field

[0001] This invention belongs to the field of welding equipment, specifically relating to an intelligent welding device and control method for power transmission tower structural components. Background Technology

[0002] As the core supporting structure of power transmission lines, power transmission towers are widely used in the construction of power infrastructure such as ultra-high voltage power grids and new energy grid integration. Their manufacturing and operation quality directly affects the safety and stability of the power grid. With the development of my country's power system construction, the market demand for power transmission towers continues to rise. During the manufacturing, renovation, and dismantling of power transmission towers, a large amount of leftover angle steel members is generated. These leftover tower members are difficult to directly use in the construction of new power transmission tower structures due to their scattered lengths and substandard specifications.

[0003] Most of the scrap materials are directly discarded or processed as raw materials for recycling. Furthermore, the angle steel members used in the construction of power transmission towers have thick walls and large weight per unit length, making manual operation inefficient and difficult. Only some of the longer scrap materials are reused after manual welding, resulting in low utilization of steel resources and material waste. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides an intelligent welding device and control method for power tower structural components. This device can adapt to scattered tower pole scraps, reduce the difficulty and intensity of manual operation, improve welding efficiency, significantly increase the reuse rate of scraps, reduce steel resource waste and overall construction costs, and ensure that the connecting components meet the safety operation requirements of the power tower structure.

[0005] The specific technical solution adopted in this invention is as follows:

[0006] A smart welding device for power tower structural components includes a welding robot and welding fixtures. The welding robot is disposed on one side of the welding fixtures. The welding fixtures include a base and multiple sets of support devices disposed on the base. Each support device includes a mounting frame disposed vertically on the base. The mounting frame has a plate-like structure. A rotating disk is disposed on the side wall of the mounting frame. The rotating disk can rotate relative to the mounting frame. The mounting frame is provided with through clearance holes. The rotating disk is provided with clamping grooves. The excess tower material passes through the clamping grooves and clearance holes of the multiple support devices and is supported below the welding robot.

[0007] Support rollers are provided on the side wall of the mounting frame. Multiple support rollers are arranged around the periphery of the rotating disk. The rotating disk is rotated on both sides of the mounting frame by means of the support rollers. The clamping groove has an L-shaped cross-section. Friction conveying rollers are provided on the outer surface of the rotating disk. The friction conveying rollers abut against the tower rod residue and form a rolling fit.

[0008] The friction conveying roller is connected to a drive motor, which is fixedly mounted on the surface of the rotating disk. One friction conveying roller is provided on each side of the L-shaped clamping groove. The friction conveying roller is located outside the corner of the clamping groove. When the outer wall of the tower rod residue abuts against the friction conveying roller, the outer corner of the tower rod residue is located at the center of the rotating disk.

[0009] A limit telescopic cylinder is fixedly installed on the back of the rotating disk. The telescopic end of the limit telescopic cylinder is provided with a limit bolt. The end of the limit bolt has a right-angle structure and abuts against the tower rod residue located in the clamping groove by means of the telescopic extension and retraction of the limit telescopic cylinder.

[0010] The mounting bracket is mounted on the base via a movable seat, and the mounting bracket slides with a slide rail on the base via the movable seat. The mounting bracket is also equipped with a drive gear, which meshes with teeth on the outer ring of the rotating disk for transmission.

[0011] The drive gear is rotated with the mounting bracket via a spline sleeve. A rotating motor is installed on the base, and the output end of the rotating motor is connected to a drive shaft. The drive shaft passes through multiple sets of spline sleeves of the support device in sequence and forms a retractable and slidable rotational engagement with the spline sleeves. The drive shaft is arranged parallel to the slide rail on the base.

[0012] The welding robot is also equipped with a positioning clamp at its end, and the positioning clamp and the welding torch are located on the two sides of the welding robot, respectively.

[0013] The welding robot is mounted on a welding frame via a movable trolley. The welding frame is equipped with a track parallel to the slide rail on the base. Multiple sets of support devices are provided on both sides of the welding robot's movement range.

[0014] A control method for an intelligent welding device for power transmission tower structural components, the control method comprising the following steps.

[0015] S1. The tower rod scrap is transported to the support device by the conveyor belt on the feeding side of the support device. At this time, one side of the L-shaped structure of the clamping groove on the support device is horizontal and the other side is vertically upward. Adjust the position of the tower rod scrap and insert the tower rod scrap into the clamping groove by the rolling of the conveyor belt. The friction conveying roller on the rotating disk rotates synchronously and inserts the tower rod scrap into the mounting frame.

[0016] S2. Multiple sets of support devices relay the tower rod scrap material until the tower rod scrap material is located on the output side of the welding robot, and then the second tower rod scrap material is fed in in the same way;

[0017] S3. Rotate the rotating disc until the clamping groove forms a V-shape with the horizontal plane, and extend the limit bolt to fix the remaining tower rod material;

[0018] S4. Adjust the position of the welding robot so that the welding torch is aligned with the welding gap formed between the two tower rod scraps, and complete the inner surface welding of the tower rod scraps according to the preset trajectory;

[0019] S5. The rotating disk continues to rotate 180°, exposing the outside of the tower rod residue to the welding gun and completing the external welding;

[0020] S6. After welding is completed, the rotating disk is reset in the reverse direction. Repeat the above steps until the welding of the remaining tower material meets the design length, then unload the material.

[0021] In step S2, before the second tower rod scrap is fed in, the welding robot moves to the end of the first tower rod scrap and places the positioning clamp at the end of the first tower rod scrap. When the second tower rod scrap is delivered, the welding gap width is adjusted by the contact of the positioning clamp with the two tower rod scraps. Then the welding robot is withdrawn from the welding gap and the welding torch is used to complete the preset welding action.

[0022] The beneficial effects of this invention are:

[0023] This invention uses welding fixtures to support tower rod scraps of varying lengths and works in conjunction with a welding robot to complete the welding process. During welding, the rotation of the rotating disk ensures that the welds on both sides of the tower rod scrap are welded, allowing even thicker tower rod scraps to be fully welded. Furthermore, the rotation process during welding does not require manual intervention, which helps improve work efficiency and reduce the labor intensity of personnel. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention;

[0025] Figure 2 for Figure 1 An enlarged schematic diagram of part A in the middle;

[0026] Figure 3 for Figure 1 A lateral view;

[0027] Figure 4 This is a schematic diagram showing the state of the rotating disc when receiving material;

[0028] Figure 5 This is a schematic diagram of the rotating disk during welding of the inner surface;

[0029] Figure 6 This is a schematic diagram showing the rotating disk outside the welding area;

[0030] In the attached diagram, 1 is the welding robot, 2 is the base, 3 is the mounting frame, 4 is the rotating disk, 5 is the clamping groove, 6 is the support roller, 7 is the friction conveying roller, 8 is the drive motor, 9 is the limit telescopic cylinder, 10 is the limit bolt, 11 is the drive gear, 12 is the spline sleeve, 13 is the transmission shaft, 14 is the positioning clamp, and 15 is the welding moving frame. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0032] Specific implementation examples Figure 1 , Figure 2 and Figure 3 As shown, the present invention is an intelligent welding device for power tower structural components, including a welding robot 1 and a welding fixture. The welding robot 1 is disposed on one side of the welding fixture. The welding fixture includes a base 2 and multiple sets of support devices disposed on the base 2. The support devices include a mounting frame 3 disposed vertically on the base 2. The mounting frame 3 has a plate-like structure. A rotating disk 4 is disposed on the side wall of the mounting frame 3. The rotating disk 4 can rotate relative to the mounting frame 3. The mounting frame 3 is provided with a through clearance hole. The rotating disk 4 is provided with a clamping groove 5. The tower rod scrap passes through the clamping groove 5 and clearance hole of the multiple support devices and is supported below the welding robot 1.

[0033] This invention uses welding fixtures to support tower rod scraps of varying lengths and works in conjunction with a welding robot 1 to complete the welding process. During welding, the rotation of the rotating disk 4 ensures that the welds on both sides of the tower rod scrap are welded, allowing even thicker tower rod scraps to be fully welded. Furthermore, the rotation process during welding does not require manual intervention, which helps improve work efficiency and reduce the labor intensity of personnel.

[0034] The mounting bracket 3 is provided with clearance holes. The diameter of the clearance holes is larger than the cross-sectional dimensions of the tower rod scrap and smaller than the outer diameter of the rotating disk 4. This facilitates the installation and deployment of the rotating disk 4 and also avoids the clearance holes affecting the passage of the tower rod scrap.

[0035] Furthermore, a support roller 6 is provided on the side wall of the mounting frame 3. Multiple support rollers 6 are provided around the periphery of the rotating disk 4. The rotating disk 4 is rotatably mounted on both sides of the mounting frame 3 by means of the support rollers 6. The clamping groove 5 has an L-shaped cross-section. A friction conveying roller 7 is provided on the outer side of the rotating disk 4. The friction conveying roller 7 abuts against the tower rod residue and forms a rolling fit.

[0036] With the support of the support roller 6, the rotating disk 4 can rotate around its own axis on the mounting frame 3. The roller surface of the friction conveying roller 7 slightly penetrates into the groove of the clamping groove 5 to avoid direct friction between the tower rod residue and the rotating disk 4, thereby reducing the loss of the tower rod galvanized layer and reducing the area for subsequent protective layer repair.

[0037] Furthermore, such as Figure 3 As shown, the friction conveying roller 7 is connected to a drive motor 8, which is fixedly mounted on the surface of the rotating disk 4. One friction conveying roller 7 is provided on each side of the L-shaped clamping groove 5. The friction conveying roller 7 is located on the outside of the corner of the clamping groove 5. When the outer wall of the tower rod residue abuts against the friction conveying roller 7 for support, the outer corner of the tower rod residue is located at the center of the rotating disk 4.

[0038] In this embodiment, the residual tower material is brought into the clamping groove 5 by the friction conveying roller 7 and then tightened by the limiting telescopic cylinder 9. The outer corner of the residual tower material is located at the center of the preset rotating disk 4, which makes it easier to set the coordinate origin of the welding robot 1 and to adjust the preset program of the welding robot 1.

[0039] Furthermore, a limiting telescopic cylinder 9 is fixedly installed on the back of the rotating disk 4. A limiting bolt 10 is provided at the telescopic end of the limiting telescopic cylinder 9. The end of the limiting bolt 10 has a right-angle structure and abuts against the tower rod residue located in the clamping groove 5 by means of the telescopic extension and retraction of the limiting telescopic cylinder 9.

[0040] like Figure 5 As shown, when the limiting bolt 10 extends along the diagonal direction of the clamping groove 5, the L-shaped tower rod scrap can be automatically aligned under the support and guidance of the friction conveying roller 7 by the pushing of the limiting bolt 10. This ensures that both sides of the tower rod scrap are in contact with the corresponding friction conveying roller 7, and the positioning is completed by the limiting telescopic cylinder 9 and the rotating disk 4. The limiting telescopic cylinder 9 is fixedly installed on the back of the rotating disk 4, so that the positioned tower rod scrap and the rotating disk 4 form a stable connection. Furthermore, since the rotating disk 4 is symmetrically arranged on both sides of the mounting frame 3, even if the tower rod scrap is short, it can be tightened by the rotating disk 4 on both sides in conjunction with the limiting telescopic cylinder 9, thereby achieving the fixation of the tower rod scrap by a single support device. When the tower rod scrap is long, the position of the moving seat and the base 2 can be adjusted by personnel, and two or more sets of support devices can be used for support.

[0041] Furthermore, the mounting bracket 3 is mounted on the base 2 by means of a movable seat, and the mounting bracket 3 forms a sliding engagement with the slide rail provided on the base 2 by means of the movable seat. The mounting bracket 3 is also provided with a drive gear 11, which meshes with the teeth of the gears provided on the outer ring of the rotating disk 4 for transmission.

[0042] The drive gear 11 is rotated with the mounting bracket 3 via the spline sleeve 12. The base 2 is equipped with a rotating motor, and the output end of the rotating motor is connected to a drive shaft 13. The drive shaft 13 passes through the spline sleeves 12 of multiple support devices in sequence and forms a retractable and slidable rotational engagement with the spline sleeves 12. The drive shaft 13 is arranged parallel to the slide rail on the base 2.

[0043] The present invention uses a rotating motor to drive the transmission shaft 13 to rotate. The transmission shaft 13 drives the drive gear 11 to rotate through the spline sleeve 12. The drive gear 11 and the transmission shaft 13 are respectively set on both sides of the bottom of the rotating disk 4. The two sets rotate synchronously and complement each other, and are pressed together by the gravity of the rotating disk 4 itself, so as to ensure that the angle of the rotating disk 4 of different support devices is consistent.

[0044] Furthermore, the welding robot 1 is also provided with a positioning clamp 14 at its end, and the positioning clamp 14 and the welding torch are respectively located on both sides of the welding robot 1.

[0045] like Figure 1 As shown, the welding robot 1 is mounted on the welding moving frame 15 by means of a moving trolley. The welding moving frame 15 is provided with a track parallel to the slide rail on the base 2. Multiple sets of support devices are provided on both sides of the moving range of the welding robot 1.

[0046] This invention also discloses a control method for an intelligent welding device for power tower structural components, the control method comprising the following steps:

[0047] S1. The tower rod scrap is transported to the support device by the conveyor belt on the feeding side of the support device. At this time, one side of the L-shaped structure of the clamping groove 5 on the support device is horizontal and the other side is vertically upward. Adjust the position of the tower rod scrap and insert the tower rod scrap into the clamping groove 5 by the rolling of the conveyor belt. The friction conveying roller 7 on the rotating disk 4 rotates synchronously and inserts the tower rod scrap into the mounting frame 3.

[0048] S2. Multiple sets of support devices relay the tower rod scrap material until the tower rod scrap material is located on the output side of welding robot 1, and then the second tower rod scrap material is fed in in the same way;

[0049] On-site manual control maintains welding space between the end of the first tower rod scrap and the rotating disk 4, avoiding interference with the welding robot 1's welding action. When the second tower rod scrap is fed in, the friction conveying roller 7 used to support the first tower rod scrap stops and brakes, thus keeping the position of the first tower rod scrap unchanged, waiting for the second tower rod scrap to arrive.

[0050] S3. Rotate the rotating disk 4 until the clamping groove 5 forms a V-shape with respect to the horizontal plane, and extend the limit bolt 10 to fix the remaining tower rod material;

[0051] In this step, by rotating disk 4, as... Figure 5 As shown, relative Figure 4 After rotating 45°, the clamping groove 5 becomes V-shaped, and then it is pushed out by the limit bolt 10 to position the remaining tower rod material.

[0052] S4. Adjust the position of welding robot 1 so that the welding gun is aligned with the welding gap formed between the two tower rod scraps, and complete the inner surface welding of the tower rod scraps according to the preset trajectory;

[0053] Because the tower rod scraps have a large wall thickness, the chamfering was completed in the process before welding, which facilitates full welding. Once the two tower rod scraps are joined together to form a welding gap, welding can begin directly.

[0054] S5. The rotating disk 4 continues to rotate 180°, exposing the outside of the tower rod residue to the welding gun and completing the external welding;

[0055] S6. After welding is completed, the rotating disk 4 is reset in the reverse direction to avoid the connecting wires and pressure pipes on the back of the rotating disk 4 from getting tangled. Repeat the above steps until the remaining tower material is welded to the required length and then unload the material.

[0056] Furthermore, such as Figure 3 As shown, in step S2, before the second tower rod scrap is fed in, the welding robot 1 moves to the end of the first tower rod scrap and places the positioning clamp 14 at the end of the first tower rod scrap. When the second tower rod scrap is delivered, the welding gap width is adjusted by the contact of the positioning clamp 14 between the two tower rod scraps. Then the welding robot 1 is withdrawn from the welding gap and the welding gun is used to complete the preset welding action.

[0057] During welding, the operator adjusts the welding robot 1 to the end of the first tower rod scrap. The welding robot 1 rotates 180° so that the positioning clamp 14 is inserted vertically into the end of the first tower rod scrap and abuts against the end. After the second tower rod scrap is in place, the two tower rod scraps work together with the friction conveying roller 7 to abut against the positioning clamp 14. Then the welding robot 1 moves vertically to pull out the positioning clamp 14, forming a weld that meets the size requirements, which facilitates the smooth operation of the preset welding program.

Claims

1. An intelligent welding device for power tower structural components, comprising a welding robot (1) and welding fixtures, wherein the welding robot (1) is disposed on one side of the welding fixtures, characterized in that: The welding fixture includes a base (2) and multiple sets of support devices on the base (2). The support devices include a mounting frame (3) set vertically on the base (2). The mounting frame (3) has a plate-like structure. A rotating disk (4) is provided on the side wall of the mounting frame (3). The rotating disk (4) can rotate relative to the mounting frame (3). A through clearance hole is provided on the mounting frame (3). A clamping groove (5) is provided on the rotating disk (4). The tower rod scrap passes through the clamping groove (5) and clearance hole of the multiple support devices and is supported below the welding robot (1).

2. The intelligent welding device for power tower structural components according to claim 1, characterized in that: Support rollers (6) are provided on the side wall of the mounting frame (3). Multiple support rollers (6) are provided around the periphery of the rotating disk (4). The rotating disk (4) is rotated on both sides of the mounting frame (3) by means of the support rollers (6). The clamping groove (5) has an L-shaped cross section. Friction conveying rollers (7) are provided on the outer side of the rotating disk (4). The friction conveying rollers (7) abut against the tower rod residue and form a rolling fit.

3. The intelligent welding device for power tower structural components according to claim 2, characterized in that: The friction conveying roller (7) is connected to a drive motor (8), which is fixedly mounted on the surface of the rotating disk (4). There is one friction conveying roller (7) on each side of the L-shaped clamping groove (5). The friction conveying roller (7) is located outside the corner of the clamping groove (5). When the outer wall of the tower rod residue abuts against the friction conveying roller (7), the outer corner of the tower rod residue is located at the center of the rotating disk (4).

4. The intelligent welding device for power tower structural components according to claim 2, characterized in that: A limiting telescopic cylinder (9) is fixedly installed on the back of the rotating disk (4). A limiting bolt (10) is installed at the telescopic end of the limiting telescopic cylinder (9). The end of the limiting bolt (10) is a right-angle structure and abuts against the tower rod residue located in the clamping groove (5) by means of the telescopic extension of the limiting telescopic cylinder (9).

5. The intelligent welding device for power tower structural components according to claim 1, characterized in that: The mounting bracket (3) is mounted on the base (2) by means of a movable seat. The mounting bracket (3) forms a sliding fit with the slide rail provided on the base (2) by means of the movable seat. The mounting bracket (3) is also provided with a drive gear (11). The drive gear (11) meshes with the teeth of the gears provided on the outer ring of the rotating disk (4) for transmission.

6. The intelligent welding device for power tower structural components according to claim 5, characterized in that: The drive gear (11) is rotated with the mounting bracket (3) by means of the spline sleeve (12). The base (2) is equipped with a rotating motor, and the output end of the rotating motor is connected to the drive shaft (13). The drive shaft (13) passes through the spline sleeves (12) of multiple support devices in sequence and forms a retractable and sliding rotational fit with the spline sleeves (12). The drive shaft (13) is parallel to the slide rail on the base (2).

7. The intelligent welding device for power tower structural components according to claim 1, characterized in that: The welding robot (1) is also provided with a positioning clamp (14) at its end, and the positioning clamp (14) and the welding torch are located on both sides of the welding robot (1).

8. The intelligent welding device for power tower structural components according to claim 1, characterized in that: The welding robot (1) is mounted on the welding moving frame (15) by means of a moving trolley. The welding moving frame (15) is provided with a track parallel to the slide rail on the base (2). Multiple sets of support devices are provided on both sides of the moving range of the welding robot (1).

9. A control method for an intelligent welding device for power tower structural components, based on the intelligent welding device for power tower structural components as described in claim 1, characterized in that: The control method includes the following steps. S1. The tower rod scrap is transported to the support device by means of the conveyor belt on the feeding side of the support device. At this time, one side of the L-shaped structure of the clamping groove (5) on the support device is horizontal and the other side is vertically upward. Adjust the position of the tower rod scrap and insert the tower rod scrap into the clamping groove (5) by means of the rolling of the conveyor belt. The friction conveying roller (7) on the rotating disk (4) rotates synchronously and inserts the tower rod scrap into the mounting frame (3). S2. Multiple sets of support devices relay the tower rod residue until the tower rod residue is located on the output side of the welding robot (1), and then the second tower rod residue is fed in in the same way; S3. Rotate the rotating disk (4) until the clamping groove (5) forms a V-shape relative to the horizontal plane, and extend the limiting bolt (10) to fix the remaining tower rod material; S4. Adjust the position of the welding robot (1) so that the welding gun is aligned with the welding gap formed between the two tower rods and completes the inner surface welding of the tower rods according to the preset trajectory; S5. The rotating disk (4) continues to rotate 180°, exposing the outside of the tower rod residue to the welding gun and completing the outside welding; S6. After welding is completed, rotate the disk (4) to reverse and reset. Repeat the above steps until the welding of the remaining tower material meets the design length and then unload the material.

10. The control method according to claim 9, characterized in that: In step S2, before the second tower rod scrap is fed in, the welding robot (1) moves to the end of the first tower rod scrap and places the positioning clamp (14) at the end of the first tower rod scrap. When the second tower rod scrap is delivered, the welding gap width is adjusted by the contact of the two tower rod scraps with the positioning clamp (14). Then the welding robot (1) is pulled out of the welding gap and the welding gun is used to complete the preset welding action.

Images