Automatic welding system and welding method of welding robot

Abstract

The invention relates to an automatic welding system of a welding robot, which comprises a mechanical arm, a welding gun mounted at the tail end of the mechanical arm and a control system, and further comprises a multi-channel welding wire supply assembly, a welding wire conveying assembly and a welding wire conveying assembly, the welding wire splicing assembly is arranged between the welding wire supply assembly and the welding gun; the welding wire connecting mechanism is arranged between the first clamping mechanism and the second clamping mechanism; the wire storage path structure is used for storing or releasing the length of the welding wire by changing the path length; the detection assembly comprises a welding wire length detection unit or a rotating speed detection unit; a welding wire tension detection unit; the control system is electrically connected with the welding wire supply assembly, the welding wire splicing assembly and the detection assembly, and when the current welding wire reaches a preset residual threshold value, the second clamping mechanism is controlled to clamp the welding wire to be connected; a welding wire connecting mechanism is controlled to complete welding wire connection; and in the connecting process, the buffering wire storage assembly is controlled to release the welding wire so as to maintain continuous wire supply of the welding gun end.

Description

Technical Field

[0001] This invention relates to the field of welding automation technology, and in particular to a continuous wire feeding automatic welding system and its control method suitable for industrial robot welding scenarios. Specifically, it relates to an automated system that realizes continuous wire supply during the welding process based on multi-channel wire supply and wire splicing technology. Background Technology

[0002] With the continuous improvement of industrial automation, welding robots have been widely used in automobile manufacturing, pressure vessels, rail transportation, aerospace and other fields. Especially in argon arc welding (TIG) and precision welding processes, higher requirements have been placed on welding continuity, stability and weld quality.

[0003] Existing welding robots typically use a single welding wire supply method, where the welding wire is wound onto a wire roller and fed to the welding torch via a wire feeding mechanism. When the welding wire on the wire roller is depleted, the roller needs to be manually replaced and the wire re-threaded. This process presents the following problems: severe welding interruptions: welding must be stopped during wire replacement, affecting production cycle; frequent manual intervention: operators need to participate frequently, resulting in high labor intensity; high safety risks: there are risks of high temperature and electric shock during replacement; and unstable welding quality: re-ignition of the arc may lead to weld defects.

[0004] Some existing technologies attempt to achieve automatic replacement by setting up multiple welding wire rollers and mechanically switching them, but such solutions still have the following shortcomings: the welding wire supply is interrupted during the switching process, making it impossible to achieve truly continuous welding; the mechanical structure is complex and its reliability is limited; it is impossible to achieve automatic connection of the welding wire ends; and it lacks intelligent prediction and control mechanisms.

[0005] Therefore, there is an urgent need for an automated welding system that can achieve continuous welding wire supply without interrupting welding, in order to improve production efficiency and welding quality. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide an automatic welding system and welding method for a welding robot.

[0007] The technical solution adopted in this invention is as follows: According to a first aspect of this application, an automated welding system for a welding robot is provided, comprising a robotic arm, a welding torch mounted at the end of the robotic arm, and a control system, further comprising: Multi-channel welding wire supply assembly: includes at least two sets of welding wire supply units, each welding wire supply unit including: welding wire roller; active wire feeding drive mechanism, the active wire feeding drive mechanism including wire feeding motor and drive wheel in contact with welding wire; and clamping wheel arranged in cooperation with the drive wheel for applying clamping force to welding wire; Welding wire splicing assembly: disposed between the welding wire supply assembly and the welding torch, including a linear guide channel; a first clamping mechanism and a second clamping mechanism disposed on both sides of the linear guide channel; and a welding wire connecting mechanism disposed between the first clamping mechanism and the second clamping mechanism; in: The first clamping mechanism is used to clamp the currently fed welding wire; The second clamping mechanism is used to clamp the welding wire to be connected; The welding wire connection mechanism is used to weld or press the ends of two welding wires together to form a continuous welding wire. Buffer wire storage assembly: disposed between the welding wire splicing assembly and the welding torch, including at least one deformable wire storage path structure; the wire storage path structure stores or releases the welding wire length by changing the path length. Detection components: including a wire length detection unit or a rotation speed detection unit; a wire tension detection unit; Control system: electrically connected to the welding wire supply component, welding wire splicing component and detection component respectively, used for: determining the current welding wire remaining status according to the signal of the detection component; when the current welding wire reaches the preset remaining threshold, controlling the second clamping mechanism to clamp the welding wire to be connected; controlling the welding wire connection mechanism to complete the welding wire connection; and controlling the buffer wire storage component to release the welding wire during the connection process to maintain continuous wire supply at the welding gun end.

[0008] Preferably, the welding wire connection mechanism includes a two-electrode clamping unit and a pulse current generating unit; the two electrodes respectively contact the end of the welding wire, and resistance welding is achieved through pulse current.

[0009] Preferably, the welding wire connection mechanism is a laser welding device, including a laser emitter and an optical path focusing assembly.

[0010] Preferably, both the first clamping mechanism and the second clamping mechanism include a fixed clamping block, a movable clamping block, and a cylinder or electric push rod for driving the movable clamping block to move.

[0011] Preferably, the linear guide channel is a straight pipe with a smooth inner wall or a guide groove structure with a low-friction bushing.

[0012] Preferably, the buffer wire storage assembly is a swing arm type structure, including a swing arm that can rotate around a fulcrum and a wire guide wheel disposed on the swing arm, and the wire path length is changed by swinging the swing arm.

[0013] Preferably, the buffer wire storage assembly is an annular wire storage structure, with the welding wire forming at least one annular storage path.

[0014] Preferably, the wire feeding drive mechanism includes a servo motor, an encoder, and a closed-loop speed control unit.

[0015] Preferably, the wire tension detection unit is a strain gauge tension sensor, and the control system adjusts the wire feeding motor speed according to the tension signal.

[0016] According to a second aspect of this application, an automatic welding method using an automatic welding system employing the above-described welding robot is provided, comprising the following steps: Step 1: Drive the first welding wire supply unit to feed welding wire to the welding gun; Step 2: Real-time monitoring of welding wire feed length or remaining amount; Step 3: When the remaining amount of welding wire is lower than the preset threshold, drive the second welding wire supply unit to feed wire to the welding wire splicing assembly; Step 4: Clamp the ends of the two welding wires respectively using the first clamping mechanism and the second clamping mechanism; Step 5: Control the welding wire connection mechanism to complete the welding wire connection; Step 6: Release the welding wire through the buffer wire storage assembly during the connection process; Step 7: After the connection is completed, the second welding wire supply unit continues to supply wire.

[0017] Compared with the prior art, the present invention has the following advantages: Achieve truly continuous welding through wire splicing technology, ensuring uninterrupted wire supply; improve welding quality, avoid re-ignition, and reduce weld defects. High degree of automation, requiring no manual intervention and reducing labor intensity. High reliability, avoiding complex mechanical switching structures and improving stability. Strong scalability, supporting various wire materials and multi-channel expansion. Intelligent control, using a predictive mechanism for pre-splitting, improves system responsiveness. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of an automatic welding system of a welding robot according to an embodiment of this application; Figure 2 yes Figure 1 Schematic diagram of the welding wire supply unit; Figure 3 yes Figure 1 Schematic diagram showing the positional structure of the welding wire splicing assembly and the buffer wire storage assembly; Figure 4 yes Figure 3 A top view of the splicing assembly of the welding wire during the splicing process; Figure 5 yes Figure 4 A schematic diagram of the main structure of the moving clamping block; Figure 6 yes Figure 3 A schematic diagram of the structure of the intermediate buffer wire storage assembly when releasing the welding wire. Detailed Implementation

[0019] 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 only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1: Automated Welding System for Welding Robots This embodiment provides an automated welding system for a welding robot. This system aims to solve the technical problems in the prior art where welding is interrupted due to wire depletion, requiring manual wire replacement, and affecting welding efficiency and weld quality. Figure 1 As shown, the system mainly includes: a multi-joint robotic arm 310, a welding torch 320 mounted at the end of the robotic arm 310, and an industrial-grade control system as the core control unit. To achieve a continuous and stable supply of welding wire, this system creatively integrates a multi-channel welding wire supply assembly 200, a welding wire splicing assembly 100, a buffer wire storage assembly 400, and a detection assembly for real-time monitoring. The control system is electrically connected to the above components, and through precise timing control and signal feedback, collaboratively completes the automatic switching and seamless splicing of welding wire.

[0021] 1. Multi-channel welding wire supply assembly like Figure 2 As shown, the multi-channel welding wire supply assembly 200 includes at least two independent welding wire supply units 210. This embodiment uses two sets as an example for illustration, but those skilled in the art will understand that, depending on actual production needs (such as frequent switching of welding wires of different materials or longer uninterrupted welding time), it can be expanded to three or more sets.

[0022] Each wire feeding unit 210 functions as an independent wire source, and its specific structure includes: a wire roller 211 for winding and storing the welding wire; and an active wire feeding drive mechanism 212. The core of this mechanism is a high-precision wire feeding motor, preferably a servo motor, whose output shaft is connected to a drive wheel 213. The drive wheel 213 has V-shaped or U-shaped grooves on its surface that match the diameter of the welding wire to increase friction. Opposite to the drive wheel is a clamping wheel 214, which provides adjustable clamping force through elastic elements such as springs or cylinders, ensuring sufficient static friction between the welding wire and the drive wheel 213, thereby achieving precise control of the wire feeding speed and amount. The wire feeding motor is preferably a servo motor with a built-in encoder, forming a closed-loop speed control unit with the control system. This allows for real-time feedback of the motor speed, ensuring that the wire feeding speed is strictly consistent with the welding process requirements, especially during splicing and when the welding speed changes, guaranteeing the smoothness of the wire feeding.

[0023] 2. Welding wire splicing assembly The welding wire splicing assembly 100 is a key component in this system for achieving continuous wire feeding; it is positioned on the wire feeding path between the multi-channel welding wire supply assembly and the welding torch. For example... Figures 3 to 5 As shown, the component includes a linear guide channel 103 for guiding and positioning the welding wire. The channel is a straight pipe with a smooth inner wall or a guide groove structure with a low-friction bushing (such as a polytetrafluoroethylene bushing), which can ensure that the ends of the welding wire from different supply units can be accurately guided to the splicing station.

[0024] On both sides of the linear guide channel, a first clamping mechanism 101 and a second clamping mechanism 102 are respectively provided. The first clamping mechanism 101 is used to clamp the welding wire currently being fed to the welding torch (hereinafter referred to as "current welding wire"), and the second clamping mechanism 102 is used to clamp the new welding wire 001 to be connected (hereinafter referred to as "welding wire to be connected"). Each clamping mechanism includes a fixed clamping block 111, a movable clamping block 112, and a driving element 113 that drives the movable clamping block to perform clamping or releasing actions. The driving element can be a pneumatic cylinder or a miniature electric push rod. The inner surface of the clamping mechanism may be provided with anti-slip teeth or wear-resistant pads to ensure that the ends of the two welding wires can be firmly fixed during subsequent splicing processes, preventing axial displacement or rotation.

[0025] The end of the movable clamping block 112 has a groove 1121 to temporarily fix the welding wire. In order to improve the fixing effect, a stop block 1122 connected by a torsion spring is provided at the top of the groove 1121. After the welding wire is spliced, the movable clamping block moves backward to push the welding wire away from the stop block 1122 and disengage from the groove 1121, waiting to be fixed with the next welding wire to be connected.

[0026] A welding wire connecting mechanism 110 is provided at a precisely aligned position between the first clamping mechanism 101 and the second clamping mechanism 102. In this embodiment, the welding wire connecting mechanism 110 is preferably a resistance welding structure, which includes two opposing electrode clamping units and a pulse current generating unit. After the first clamping mechanism and the second clamping mechanism fix and align the ends of the two welding wires, the two electrode clamping units clamp the ends of the two welding wires respectively under the drive of a micro cylinder.

[0027] The two electrode clamping units can be arranged vertically, for example, so that interference can be avoided when the second clamping mechanism 102 moves the welding wire to the welding position.

[0028] Subsequently, the pulse current generating unit applies a high-energy, short-duration pulse current to the two electrodes. According to Joule's law, the current flowing through the contact surface of the welding wire ends generates enormous heat, causing the welding wire ends to melt instantaneously and fuse together under a certain pressure (which can be provided by the electrode clamping unit) to form a strong joint. The voltage, current, and duration of the pulse current can be preset and adjusted according to the material (such as carbon steel, stainless steel, aluminum alloy, etc.) and diameter of the welding wire to ensure weld quality. In another preferred embodiment, the welding wire connection mechanism can also employ a laser welding device, including a laser emitter and an optical focusing assembly. The focused high-energy laser beam irradiates the joint between the two welding wire ends, causing them to melt and connect rapidly. Laser welding has advantages such as a small heat-affected zone, high welding precision, and applicability to a variety of materials.

[0029] 3. Buffer wire storage assembly The wire buffer assembly 400 is positioned between the wire splicing assembly 100 and the welding torch 320. Its core function is to continuously supply welding wire to the welding torch during the brief process of wire splicing. Figure 6 As shown, the buffer wire storage assembly in this embodiment adopts a swing arm structure. This structure includes a swing arm 410 that can rotate around a fixed fulcrum, and a wire guide wheel 411 disposed at one end of the swing arm 410. After the welding wire is fed out from the welding wire splicing assembly, it passes through one or more fixed wire guide wheels, then goes around the wire guide wheel on the swing arm, and finally is fed to the welding torch.

[0030] During normal welding, the control system adjusts the wire feeding speed of the active wire feed drive mechanism to maintain a dynamic balance between the amount of welding wire entering the buffer wire storage assembly and the amount of welding wire consumed by the welding torch, with the swing arm typically in an intermediate angle position. When performing a wire splicing operation, the first clamping mechanism clamps the current welding wire, temporarily interrupting the wire supply from the multi-channel wire supply assembly. However, the welding torch continues welding, consuming welding wire. At this time, the tension on the welding wire pulls the swing arm to swing in a direction that reduces the path length (e.g., clockwise), and the wire guide wheel on the swing arm moves accordingly, releasing the length of welding wire pre-stored in that path, thereby compensating for the wire gap caused by the interruption in wire supply. The swing angle range of the swing arm determines the maximum length of welding wire it can store or release, and it is typically designed to meet the time required to complete a full splicing operation (e.g., 3-5 seconds). In another preferred embodiment, the buffer wire storage assembly may also adopt an annular wire storage structure, in which the welding wire forms at least one annular storage path between several fixed wire guide wheels and one movable wire guide wheel. The circumference of the annular path is changed by the movement of the movable wire guide wheel, thereby realizing the storage and release of the welding wire.

[0031] 4. Detection Components The detection components are the sensing foundation for achieving automated control and precise splicing. They include a wire length detection unit (or rotation speed detection unit) and a wire tension detection unit.

[0032] The wire length detection unit is used to monitor the current consumption or remaining amount of welding wire in real time. In one embodiment, this unit can be implemented using a high-precision encoder mounted on the output shaft of the wire feed motor. By reading the number of pulses from the encoder and combining this with the diameter of the drive wheel, the control system can accurately calculate the length of the fed wire, thereby indirectly determining the remaining length of the welding wire on the wire roller. In another embodiment, a photoelectric sensor or a laser rangefinder can also be installed near the wire roller to directly detect the radial thickness of the wire coil on the wire roller, thereby directly determining the remaining amount.

[0033] The welding wire tension detection unit is preferably a strain gauge tension sensor, which is typically installed on the wire feeding path after the welding wire splicing assembly and before the buffer wire storage assembly. This sensor can detect the tension on the welding wire in real time and convert it into an electrical signal, which is then sent to the control system. This signal can not only be used to monitor the stability of the welding process, but more importantly, during the operation of the welding wire splicing and buffer wire storage assembly, the control system dynamically adjusts the speed of the wire feeding motor based on the tension signal. For example, when the swing arm of the buffer wire storage assembly releases the welding wire, if the detected tension is too low, the wire feeding speed can be appropriately reduced; if the tension is too high, the wire feeding speed can be increased to ensure a smooth wire feeding process and successful splicing.

[0034] 5. Control System The control system, acting as the "brain" of the entire system, typically consists of a high-performance industrial controller (such as a PLC, embedded industrial computer, or CNC system), which stores the control program for automatic splicing. The control system is electrically connected to the various motors and drivers of the multi-channel welding wire supply assembly, the various cylinders / motors and welding power supply of the welding wire splicing assembly, the position sensors (such as the swing arm angle sensor) of the buffer wire storage assembly, and various sensors of the detection assembly.

[0035] The core control logic of the control system is as follows: Status monitoring: Receive signals from the detection components in real time, especially feedback from the wire length detection unit, and continuously determine the remaining amount of wire in the currently used wire supply unit.

[0036] Prediction and Initiation: When the control system determines that the remaining amount of welding wire has reached a preset "splicing threshold" (for example, the remaining welding wire length is only enough for 5 seconds of welding or the remaining number of turns is less than 10 turns), the splicing process is immediately initiated.

[0037] Preparation of welding wire to be fed: The control system starts the wire feeding motor of the second welding wire supply unit to accurately deliver the end of the welding wire to be fed into the linear guide channel of the welding wire splicing assembly, and to the predetermined clamping position of the second clamping mechanism. During this process, the position of the welding wire end can be confirmed by a photoelectric sensor.

[0038] Clamping and Positioning: The control system issues a command to first drive the cylinder or electric push rod of the second clamping mechanism, causing its movable clamping block to move towards the fixed clamping block, firmly clamping the end of the welding wire to be connected. Subsequently, the first clamping mechanism is driven to clamp the end of the current welding wire. At this time, the ends of the two welding wires are precisely aligned within the working area of ​​the welding wire connecting mechanism, with the spacing or overlap within a preset range.

[0039] Coordinated Execution: The control system issues a command to activate the wire connection mechanism for welding or crimping. At the instant the connection mechanism begins operation, the control system simultaneously sends a "release" signal to the wire storage assembly, or, by monitoring changes in the tension signal, allows the swing arm to swing freely under the tension of the welding torch, thereby releasing the stored wire and maintaining continuous wire supply at the torch end. This stage is crucial for the coordinated control of the entire system.

[0040] Connection Completion and Switching: After the welding wire connection mechanism completes welding and confirms the joint quality is qualified (through current, time, or visual inspection), the control system issues a command, and the first clamping mechanism releases its grip on the exhausted current welding wire. At this time, the new welding wire (i.e., the original welding wire to be connected) has been connected with the subsequent welding wire through the connection mechanism, becoming the new current welding wire. The control system then adjusts the control logic, switching the wire feeding command to the wire feeding motor of the second welding wire supply unit, which continues to be responsible for feeding wire to the welding torch.

[0041] System Reset: The wire rollers in the first wire supply unit are now depleted and can be replaced manually or automatically by a roller changing device, preparing for the next splicing. Under the new wire feeding speed, the swing arm of the buffer wire storage assembly will gradually swing back to the middle position, storing a certain amount of wire again, preparing for the next splicing.

[0042] Through the aforementioned precise structural design and coordinated control, the automatic welding system of the welding robot in this embodiment achieves truly unmanned, uninterrupted continuous welding.

[0043] Example 2: Automatic Welding Method This embodiment provides an automated welding method using the automated welding system of the welding robot described in Embodiment 1 above. This method achieves seamless wire switching and continuous welding through a series of preset automated processes. The method includes the following specific steps: Step 1: Initial Welding Wire Feed Upon initiating the welding task, the control system, based on preset welding process parameters, drives the active wire feeding mechanism of the first wire supply unit. The wire feeding motor rotates at a set speed, driving the drive wheel to draw the welding wire from the wire roller. The wire passes through the linear guide channel of the wire splicing assembly (at this time, the splicing assembly does not perform clamping or connecting actions), the path of the buffer wire storage assembly, and finally exits from the end of the welding torch. After arc ignition, the welding robot automatically welds according to the preset trajectory.

[0044] Step 2: Real-time monitoring of welding wire status During the welding process, the control system monitors the status of the welding wire in real time through detection components. Specifically, the control system continuously reads the signal from the welding wire length detection unit. If the welding wire length detection unit is an encoder mounted on the wire feeding motor, the control system calculates the remaining length of the welding wire on the current welding wire roller in real time by accumulating the number of pulses and combining it with the initial total welding wire length. At the same time, the welding wire tension detection unit also feeds back the tension value to the control system in real time to monitor the smoothness of the wire feeding process.

[0045] Step 3: Judgment and Startup Preparation The control system compares the remaining length calculated in real time with a preset safety threshold (e.g., 2 meters). When the remaining length is less than or equal to this threshold, the system determines that the current welding wire is about to run out and the welding wire splicing process needs to be initiated. At this time, the control system immediately sends a start command to the second welding wire supply unit. The wire feeding motor of the second welding wire supply unit starts running, conveying the welding wire (to be connected) forward through a linear guide channel until its end reaches the predetermined clamping position within the welding wire splicing assembly. This position can be confirmed by a positioning sensor (such as a photoelectric switch) installed near the second clamping mechanism.

[0046] Step 4: Clamp the ends of the two welding wires After the welding wire end of the second welding wire supply unit is in place, the control system issues clamping commands according to a preset timing sequence. First, it controls the drive element of the second clamping mechanism to close the movable clamping block and the fixed clamping block, firmly clamping the end of the welding wire to be connected. Then, it controls the drive element of the first clamping mechanism to firmly clamp the end of the welding wire currently being fed. At this time, the ends of the two welding wires maintain a precise butt joint or slight overlap state within the working area of ​​the welding wire connection mechanism, with accurate axial positioning, preparing for connection.

[0047] Step 5: Perform wire connection After clamping and fixing the ends of the two welding wires, the control system sends a start signal to the welding wire connection mechanism. If resistance welding is used, the pulse current generating unit is activated, outputting a preset pulse current to the two electrode clamping units. This current flows through the contact interface between the ends of the two welding wires, causing the metal to melt instantaneously due to the resistance heating effect and fuse under the micro-pressure applied by the electrodes. The control system monitors the welding current, voltage, and duration in real time to ensure that the welding process conforms to the preset parameter curve. After welding is completed, the electrode clamping units are released under the control of the control system. If laser welding is used, the laser emitter emits a high-energy laser beam, scanning the joint according to a preset path and parameters to complete the connection. This step is typically completed in a very short time (e.g., 0.5 to 2 seconds).

[0048] Step 6: Coordinated release of buffer welding wire Almost simultaneously with step 5, at the instant the welding wire connection mechanism operates, the welding wire supply from the first welding wire supply unit is temporarily cut off because the first clamping mechanism has already clamped the wire. However, the welding process continues, and the welding torch continuously consumes welding wire. At this time, the control system uses the buffer wire storage assembly to compensate for this brief wire supply gap. Specifically, the wire feeding tension at the welding torch end is transmitted through the welding wire to the swing arm of the buffer wire storage assembly, overcoming the damping force or spring force of the swing arm, causing it to rotate around the fulcrum, thereby releasing the length of welding wire pre-stored in its path for the welding torch to consume. The control system monitors the swing position in real time through the angle sensor on the swing arm and can fine-tune the wire feeding speed of the second welding wire supply unit based on the feedback from the tension sensor to ensure stable wire feeding tension throughout the process.

[0049] Step 7: Switch the wire supply source and reset. After the welding wire connection mechanism completes the connection and releases the electrode, the old welding wire on the first welding wire supply unit has become integrated with the new welding wire through the connection mechanism. At this time, the control system issues a command to control the first clamping mechanism to release its jaws, and the used welding wire end is released. At this point, the welding wire on the second welding wire supply unit officially becomes the current main wire source. The control system completely switches the wire feeding command to the wire feeding motor of the second welding wire supply unit, which continues to be responsible for subsequent wire feeding tasks, maintaining the continuous welding process.

[0050] Meanwhile, as the welding wire in the first welding wire supply unit runs out, the system can issue a signal (such as an audible and visual alarm) to replace the welding wire spool. The operator can replace it at their convenience, preparing for the next automatic splicing cycle. Additionally, as the second welding wire supply unit continues to feed wire, the swing arm of the buffer wire storage assembly will gradually swing back under the force of the wire feeding thrust until it returns to its initial center position, storing a preset length of welding wire again, preparing for the next splicing cycle.

[0051] By cyclically executing the above seven steps, the automatic welding method provided in this embodiment can automatically, efficiently, and reliably complete the switching and connection of welding wires during the welding process, thereby achieving true continuous welding.

[0052] In summary, the automated welding system and method for welding robots provided in this application have the following significant advantages compared to existing technologies: Achieving true continuous welding and significantly improving production efficiency: Through the integrated multi-channel welding wire supply assembly and welding wire splicing assembly, the connection of new and old welding wires can be automatically completed without interrupting the arc or the machine. This avoids the cumbersome process of stopping the machine, manually changing the wire, and re-igniting the arc when the welding wire is exhausted, which is a traditional method. This greatly improves the operating efficiency and equipment utilization rate of automated welding production lines.

[0053] Improved welding quality and reduced weld defects: Because welding can be completed without interruption, typical welding defects such as arc craters, porosity, and lack of fusion caused by re-ignition of the arc are avoided. The continuous and stable welding process ensures the uniformity and consistency of the weld, making it particularly suitable for fields with extremely high welding quality requirements, such as aerospace, pressure vessels, and the nuclear industry.

[0054] High degree of automation, reducing manual intervention and labor intensity: The entire wire replacement and connection process is automatically completed by the control system based on sensor signals, without manual operation. This not only reduces the labor intensity of operators, but also avoids quality problems or equipment failures caused by human error (such as poor wire feeding or improper end treatment).

[0055] The system boasts high reliability and a sophisticated structural design: It employs wire splicing technology to replace complex mechanical wire switching structures (such as multi-wire reel switching turrets), significantly reducing moving parts and improving overall system reliability and stability. The ingenious design of the buffer wire storage assembly ensures continuous wire supply to the welding torch during splicing, achieving perfect electrical and mechanical coordination.

[0056] Highly scalable and adaptable to various welding processes: The system adopts a modular design, and the multi-channel welding wire supply assembly can be flexibly expanded as needed. It can not only be used for long-term continuous welding, but also for automatic switching of welding wires of different materials and specifications, meeting the composite application needs of various welding processes. At the same time, the welding wire connection mechanism can select resistance welding or laser welding according to the welding wire material, making it highly adaptable.

[0057] Intelligent control and predictive maintenance: The control system enables predictive pre-start splicing by real-time detection of the remaining welding wire, avoiding unexpected downtime caused by sudden wire depletion. Simultaneously, the system's real-time monitoring of parameters such as wire feed speed, tension, and motor current provides data support for equipment condition monitoring and predictive maintenance.

[0058] It should be noted that the above detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0059] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0060] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented in sequences other than those illustrated or described herein.

[0061] 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 apparatus that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or apparatus.

[0062] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways, such as rotated 90 degrees or in other orientations, and the spatial relative descriptions used herein will be interpreted accordingly.

[0063] In the detailed description above, reference has been made to the accompanying drawings, which form part of this document. In the drawings, similar symbols typically identify similar parts unless the context otherwise indicates otherwise. The illustrated embodiments described in the detailed specification, drawings, and claims are not intended to be limiting. Other embodiments may be used and other changes may be made without departing from the spirit or scope of the subject matter presented herein.

[0064] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automated welding system for a welding robot, comprising a robotic arm, a welding torch mounted at the end of the robotic arm, and a control system, characterized in that, Also includes: Multi-channel welding wire supply assembly: includes at least two sets of welding wire supply units, each welding wire supply unit including: welding wire roller; active wire feeding drive mechanism, the active wire feeding drive mechanism including wire feeding motor and drive wheel in contact with welding wire; and clamping wheel arranged in cooperation with the drive wheel for applying clamping force to welding wire; Welding wire splicing assembly: disposed between the welding wire supply assembly and the welding torch, including a linear guide channel; a first clamping mechanism and a second clamping mechanism disposed on both sides of the linear guide channel; and a welding wire connecting mechanism disposed between the first clamping mechanism and the second clamping mechanism; in: The first clamping mechanism is used to clamp the currently fed welding wire; The second clamping mechanism is used to clamp the welding wire to be connected; The welding wire connection mechanism is used to weld or press the ends of two welding wires together to form a continuous welding wire. Buffer wire storage assembly: disposed between the welding wire splicing assembly and the welding torch, including at least one deformable wire storage path structure; the wire storage path structure stores or releases the welding wire length by changing the path length. Detection components: including a wire length detection unit or a rotation speed detection unit; a wire tension detection unit; Control system: electrically connected to the welding wire supply component, welding wire splicing component and detection component respectively, used for: determining the current welding wire remaining status according to the signal of the detection component; when the current welding wire reaches the preset remaining threshold, controlling the second clamping mechanism to clamp the welding wire to be connected; controlling the welding wire connection mechanism to complete the welding wire connection; and controlling the buffer wire storage component to release the welding wire during the connection process to maintain continuous wire supply at the welding gun end.

2. The automatic welding system of the welding robot according to claim 1, characterized in that, The welding wire connection mechanism includes a two-electrode clamping unit and a pulse current generating unit; the two electrodes respectively contact the end of the welding wire, and resistance welding is achieved through pulse current.

3. The automatic welding system of the welding robot according to claim 2, characterized in that, The welding wire connection mechanism is a laser welding device, which includes a laser emitter and an optical path focusing component.

4. The automatic welding system of the welding robot according to claim 1, characterized in that, Both the first clamping mechanism and the second clamping mechanism include a fixed clamping block, a movable clamping block, and a cylinder or electric push rod for driving the movable clamping block to move.

5. The automatic welding system of the welding robot according to claim 1, characterized in that, The linear guide channel is a straight pipe with a smooth inner wall or a guide groove structure with a low-friction bushing.

6. The automatic welding system of the welding robot according to claim 1, characterized in that, The buffer wire storage assembly is a swing arm type structure, including a swing arm that can rotate around a fulcrum and a wire guide wheel set on the swing arm, and the wire path length is changed by swinging the swing arm.

7. The automatic welding system of the welding robot according to claim 1, characterized in that, The buffer wire storage assembly is a ring-shaped wire storage structure, with the welding wire forming at least one ring-shaped storage path.

8. The automatic welding system of the welding robot according to claim 7, characterized in that, The wire feeding drive mechanism includes a servo motor, an encoder, and a closed-loop speed control unit.

9. The automatic welding system of the welding robot according to claim 8, characterized in that, The wire tension detection unit is a strain gauge tension sensor, and the control system adjusts the wire feeding motor speed according to the tension signal.

10. An automatic welding method using an automatic welding system employing a welding robot according to any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Drive the first welding wire supply unit to feed welding wire to the welding gun; Step 2: Real-time monitoring of welding wire feed length or remaining amount; Step 3: When the remaining amount of welding wire is lower than the preset threshold, drive the second welding wire supply unit to feed wire to the welding wire splicing assembly; Step 4: Clamp the ends of the two welding wires respectively using the first clamping mechanism and the second clamping mechanism; Step 5: Control the welding wire connection mechanism to complete the welding wire connection; Step 6: Release the welding wire through the buffer wire storage assembly during the connection process; Step 7: After the connection is completed, the second welding wire supply unit continues to supply wire.

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