Six-axis industrial robot automatic welding system and device

Abstract

The invention relates to the technical field of industrial robots, in particular to a six-axis industrial robot automatic welding system and device.The six-axis industrial robot automatic welding system comprises an automatic welding module, a six-axis robot body serves as a core carrier, six-joint servo driving is cooperatively controlled based on a visual sensor probe, a welding gun is linked to achieve automatic welding, and intelligent path planning is achieved; an optimal welding track is automatically generated; the fusion depth monitoring module is used for emitting laser rays through a fusion depth sensor, irradiating the laser rays on the cross section of the welding seam which is just cooled, capturing the deformation outline of the laser rays on the cross section of the welding seam through a camera in the laser fusion depth sensor, measuring the surplus height and the fusion width of the welding seam, calculating the fusion depth according to a calibration model and monitoring the fusion depth in real time; and the heat dissipation guarantee module is used for controlling the temperature of the visual sensor probe, the temperature of the fusion depth sensor and the temperature of the servo motor in the joint within a tolerance range by adopting an air cooling or water cooling mode. The system is high in automation degree, accurate in fusion depth monitoring, comprehensive in heat dissipation protection, compact in structure and high in adaptability, and the problems that the fusion depth of a traditional welding system cannot be controlled in real time, core components are prone to failure at high temperature, sensors are prone to being interfered by splashing dust, and welding precision and stability are insufficient are solved.

Description

Technical Field

[0001] This invention relates to the field of industrial robot technology, and in particular to a six-axis industrial robot automatic welding system and device. Background Technology

[0002] While existing six-axis industrial robot automated welding technology achieves basic automation, it suffers from significant shortcomings in precise welding quality control, heat dissipation and protection of core components, and adaptability to complex working conditions, making it difficult to meet the demands of high-precision, long-term continuous welding. Traditional technologies rely heavily on manual teaching and path planning, lacking precise visual guidance and dynamic correction capabilities, resulting in limited weld seam tracking accuracy and susceptibility to surface defects caused by workpiece deformation and tooling errors. More critically, penetration depth, a key indicator determining the internal quality of the weld, can only be assessed through post-weld metallographic testing or experience using traditional technologies, failing to achieve real-time monitoring during welding. This often leads to fatal defects such as incomplete fusion and burn-through, resulting in high rework rates and difficulty in adapting to high-end applications such as pressure vessels and engineering machinery.

[0003] Meanwhile, the high temperature radiated by the welding arc and the high-load heat generated by the joint servo motors are superimposed. Traditional heat dissipation methods, which rely on natural cooling or simple localized cooling, cannot effectively cool the joints, vision sensor probes, and penetration depth sensors. This leads to high-temperature aging and accuracy drift of the joint servo motors, and damage or accuracy degradation of the sensor probes due to high temperatures and spatter, significantly shortening equipment lifespan and causing frequent downtime for maintenance, thus impacting production efficiency. Furthermore, the sensor probes lack targeted protection designs, making them susceptible to corrosion from welding spatter and dust, further exacerbating the problem of decreased monitoring accuracy and resulting in insufficient overall system stability and reliability. To address these issues, we propose a six-axis industrial robot automated welding system and device. Summary of the Invention

[0004] Based on the technical problems existing in the background technology, the present invention proposes a six-axis industrial robot automatic welding system and device, which has the characteristics of high automation, accurate penetration monitoring, comprehensive heat dissipation and protection, compact structure and strong adaptability. It solves the problems of traditional welding systems, such as the inability to control penetration in real time, easy failure of core components at high temperatures, easy interference of sensors by splashing dust, and insufficient welding accuracy and stability.

[0005] This invention provides the following technical solution: a six-axis industrial robot automatic welding system, comprising:

[0006] The automatic welding module uses a six-axis robot body as the core carrier, and coordinates the six joint servo drive based on vision sensor probes to link the welding gun to achieve automated welding. It has intelligent path planning and automatically generates the optimal welding trajectory.

[0007] The weld penetration monitoring module emits a laser line through a weld penetration sensor, which illuminates the cross-section of the weld that has just cooled. The camera inside the laser weld penetration sensor captures the deformation profile of the laser line on the weld cross-section, measures the weld reinforcement and weld width, calculates the weld penetration based on the calibration model, and monitors it in real time.

[0008] The heat dissipation module uses air cooling or water cooling to keep the temperature of the vision sensor probe, the depth sensor, and the servo motor in the joint within a tolerable range.

[0009] A six-axis industrial robot automatic welding device includes multiple robotic arms connected by joints, and a welding torch is connected to the end of each robotic arm. A sensor mounting bracket is installed on the welding torch, and a penetration depth sensor and a vision sensor probe are provided on the sensor mounting bracket.

[0010] Multiple joints are equipped with a water-cooling component 1, and the sensor mounting bracket is equipped with a water-cooling component 2. Two adjacent water-cooling components 1 are connected by a water-cooling pipe 1, and the water-cooling components 1 and 2 are connected by a water-cooling pipe 2.

[0011] Preferably, the joint includes a motor end and a moving end. A servo motor is installed inside the motor end, and a gear is connected to the shaft of the servo motor. A transmission block that meshes with the gear is provided inside the moving end. The servo motor is used to drive the moving end to move through the gear and the transmission block.

[0012] The water-cooling assembly includes a water-cooling cavity and a heat sink. The water-cooling cavity is disposed in the motor end and is attached to the outer wall of the servo motor. One end of the heat sink is connected to the outer wall of the servo motor, and the other end is inserted into the water-cooling cavity.

[0013] Preferably, the moving end has a cavity, and the outer shell of the moving end has an air inlet baffle and an air outlet baffle at the position corresponding to the cavity. The gear or transmission block has a ventilation hole that connects the air inlet baffle and the air outlet baffle.

[0014] Preferably, the air outlet baffle is provided with a fan for ventilation and heat dissipation.

[0015] Preferably, a temperature sensor for monitoring temperature changes inside the moving end is installed inside the cavity.

[0016] Preferably, both the melt depth sensor and the vision sensor probe are equipped with transparent anti-splash protective covers.

[0017] Preferably, the melt depth sensor is fixed to the sensor mounting bracket by a mounting base;

[0018] The second water-cooling component includes a second water-cooling cavity and a second heat sink. The second water-cooling cavity is located at the position corresponding to the mounting base of the sensor mounting bracket. One end of the second heat sink is connected to the mounting base, and the other end is inserted into the second water-cooling cavity.

[0019] Preferably, the sensor mounting bracket is further provided with an air cooling component, which is tilted at an angle to the splash guard to clean the dust on the splash guard and reduce its internal temperature.

[0020] Preferably, the air-cooling assembly is mounted on the sensor mounting bracket via a nozzle bracket and connected to an air duct that provides dry compressed air.

[0021] This invention provides a six-axis industrial robot automatic welding system and device. It uses a built-in camera in the sensor to capture the laser deformation profile of the cross-section of the cooled weld, accurately calculates the weld reinforcement height and weld width, and combines the calibration model to estimate the weld depth. This enables non-contact real-time monitoring of weld depth during welding, eliminating inherent quality defects at the source, eliminating the need for destructive testing afterward, and improving welding consistency.

[0022] In terms of heat dissipation and protection, an integrated water-cooling design is adopted. The joint has a built-in water-cooling component 1 that is interconnected, and the sensor mounting bracket is equipped with a water-cooling component 2. The water-cooling linkage of the entire system is achieved through water-cooling pipes, which can simultaneously control the temperature of the joint servo motor, vision sensor probe, and penetration depth sensor within the tolerance range. Compared with traditional heat dissipation, the cooling efficiency is greatly improved, avoiding accuracy drift and component aging caused by high temperature, and ensuring long-term continuous welding.

[0023] Meanwhile, the sensor is integrated into a dedicated mounting bracket, along with a protective structure and water-cooling, effectively resisting welding spatter and dust corrosion, balancing probe heat dissipation and physical protection, and extending the sensor's lifespan. Furthermore, the automated welding module relies on vision sensors for collaborative control, combined with intelligent path planning to generate optimal trajectories, balancing automation efficiency and weld seam tracking accuracy. It is suitable for multi-process, high-precision welding scenarios, and its overall performance far surpasses traditional technologies. Attached Figure Description

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

[0025] Figure 2 This is a schematic diagram of the heat dissipation component structure within the joint of the present invention;

[0026] Figure 3 This is a schematic diagram of the heat dissipation component structure of the melt depth sensor of the present invention.

[0027] In the diagram: 1. Robotic arm; 2. Joint; 21. Motor end; 22. Motion end; 23. Servo motor; 24. Rotating shaft; 25. Gear; 26. Transmission block; 27. Water-cooled cavity one; 28. Heat sink one; 29. ​​Cavity; 210. Ventilation hole; 211. Air inlet baffle; 212. Air outlet baffle; 213. Fan; 214. Temperature sensor; 3. Welding torch; 4. Sensor mounting bracket; 41. Anti-splash protection cover; 42. Mounting base; 43. Water-cooled cavity two; 44. Heat sink two; 45. Nozzle bracket; 46. Air-cooling assembly; 47. Air duct; 5. Weld depth sensor; 6. Vision sensor probe; 7. Water-cooled pipe one; 8. Water-cooled pipe two. Detailed Implementation

[0028] 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 embodiments of the present invention, and not all embodiments. 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.

[0029] This invention provides a technical solution: a six-axis industrial robot automatic welding system, comprising:

[0030] The automatic welding module uses a six-axis robot body as the core carrier, and coordinates the six joint servo drive based on vision sensor probes to link the welding gun to achieve automated welding. It has intelligent path planning and automatically generates the optimal welding trajectory.

[0031] The weld penetration monitoring module emits a laser line through a weld penetration sensor, which illuminates the cross-section of the weld that has just cooled. The camera inside the laser weld penetration sensor captures the deformation profile of the laser line on the weld cross-section, measures the weld reinforcement and weld width, calculates the weld penetration based on the calibration model, and monitors it in real time.

[0032] The heat dissipation module uses air cooling or water cooling to keep the temperature of the vision sensor probe, the depth sensor, and the servo motor in the joint within a tolerable range.

[0033] During operation, the automatic welding module is activated first. Using the six-axis robot as its core, the vision sensor probe collects real-time information about the weld seam and molten pool, coordinating with the six-joint servo drives. Combined with built-in intelligent path planning, it automatically generates an interference-free optimal welding trajectory, precisely completing multi-pose and multi-process welding operations in conjunction with the welding torch, dynamically adapting to weld seam position deviations. Simultaneously, the weld penetration monitoring module operates. The weld penetration sensor emits a laser line towards the just-cooled weld cross-section, and an internal camera captures the laser line's deformation profile, accurately calculating the weld reinforcement height and weld width. This data is then used to calculate the internal weld penetration using a preset calibration model, enabling real-time monitoring during welding. Meanwhile, the heat dissipation module continuously operates, precisely cooling the vision sensor probe, weld penetration sensor, and joint servo motors using air or water cooling as needed, strictly controlling the temperature of each component within its tolerance range to prevent high temperatures from affecting accuracy and equipment lifespan.

[0034] The specific operation process of the melt depth monitoring module is as follows:

[0035] Preliminary calibration: Establish a penetration depth-welding parameter correlation model, input the workpiece material (carbon steel / stainless steel / aluminum alloy), thickness, bevel type, preset the penetration depth target value (e.g., 2mm), and weld formation standard (reinforcement height ≤ 0.5mm, no undercut); at the same time, calibrate the sensors and unify the measurement coordinate system (aligned with the robot base and weld coordinate system).

[0036] Real-time data acquisition: During the welding process, the weld depth sensor works synchronously, and the laser sensor emits a laser beam to illuminate the weld cross section behind the molten pool, capturing the weld depth and width data through the reflected laser.

[0037] Data analysis and deviation judgment: The control system analyzes the sensor data, compares the actual penetration depth with the target penetration depth, and simultaneously collects the weld formation (retained height, width, straightness) through the vision sensor to judge two types of deviations: ① penetration depth deviation (e.g., actual 1.5mm < target 2mm, judged as risk of incomplete fusion; actual 2.5mm > target 2mm, judged as risk of over-melting); ② forming deviation (e.g., retained height 0.8mm > standard 0.5mm, undercut occurs).

[0038] Closed-loop adaptive adjustment (core execution link), precise control in two dimensions:

[0039] Precise control of penetration depth: Dynamically adjust the core welding parameters based on the penetration depth deviation.

[0040] Insufficient penetration depth: Increase welding current (e.g., from 200A to 220A), decrease welding speed (e.g., from 30cm / min to 25cm / min), increase wire feed speed, increase deposition amount, and make up for insufficient penetration depth.

[0041] Excessive penetration: Reduce welding current, increase welding speed, and reduce welding torch extension to avoid burn-through.

[0042] Special working conditions: When welding multiple layers and multiple passes, the penetration depth of each layer is monitored in real time, and the welding parameters of the next layer are automatically adjusted to ensure that the cumulative penetration depth meets the standard.

[0043] Precise control of weld formation: Combining penetration data and visual formation data, dual adjustments ensure uniform formation.

[0044] Formation deviation (excessive weld height / undercut): Adjust the welding torch posture (such as adjusting the swing amplitude and swing frequency). If the weld height is too high, increase the swing amplitude. If there is undercut, fine-tune the welding torch tilt angle. Simultaneously fine-tune the welding voltage to optimize the flowability of the molten pool.

[0045] Workpiece deformation adaptation: The six-axis robot adjusts its trajectory by linking its joints to fine-tune the weld seam forming deviation, adapting to the weld seam offset caused by the thermal deformation of the workpiece during the welding process, and ensuring the consistency of the forming.

[0046] like Figure 1 As shown, a six-axis industrial robot automatic welding device includes multiple robotic arms 1 connected by joints 2, and a welding torch 3 is connected to the end of the robotic arm 1. A sensor mounting bracket 4 is installed on the welding torch 3, and a penetration depth sensor 5 and a vision sensor probe 6 are provided on the sensor mounting bracket 4.

[0047] Multiple joints 2 each contain a water-cooling component 1, and the sensor mounting bracket 4 contains a water-cooling component 2. Adjacent water-cooling components 1 are connected by water-cooling pipe 1 7, and water-cooling components 1 and 2 are connected by water-cooling pipe 2 8. This highly efficient water-cooling system comprehensively covers the core heat-generating components, significantly improving cooling stability compared to traditional heat dissipation methods. It prevents accuracy drift and component aging caused by high temperatures, supporting long-term continuous operation. Combining protection and monitoring, the water-cooling components and bracket provide dual protection, effectively resisting welding spatter and high-temperature corrosion, extending the sensor's lifespan. With strong adaptability, the integrated structure adapts to multi-position welding, precisely meeting the dual requirements of high-precision welding for equipment stability and quality control.

[0048] The core of the device consists of a robotic arm 1 connected by multiple joints 2. The end of the robotic arm 1 is connected to a welding torch 3. A sensor mounting bracket 4 on the welding torch 3 integrates a penetration depth sensor 5 and a vision sensor probe 6, which move synchronously with the welding torch 3. During welding, the vision sensor probe 6 collects real-time information about the weld seam and molten pool, guiding the robotic arm 1 to operate in conjunction with the welding torch 3 along a planned trajectory. Simultaneously, the penetration depth sensor 5 emits a laser line towards the just-cooled weld cross-section, capturing the laser deformation profile through an internal camera to calculate the weld height, weld width, and penetration depth, thus achieving quality monitoring during welding. The water-cooling system is activated simultaneously. Water-cooling components 1 within joint 2 are interconnected via water-cooling pipe 1 7, forming a full-area water-cooling loop for joint 2. Simultaneously, water-cooling components 2 within the sensor mounting bracket 4 are connected via water-cooling pipe 2 8, constructing an integrated water-cooling network for the entire device, continuously cooling the joint 2 servo motor 23, penetration depth sensor 5, and vision sensor probe 6.

[0049] like Figure 2 As shown, joint 2 includes a motor end 21 and a moving end 22. A servo motor 23 is installed inside the motor end 21. A gear 25 is connected to the rotating shaft 24 of the servo motor 23. A transmission block 26 that meshes with the gear 25 is provided inside the moving end 22. The servo motor 23 is used to drive the moving end 22 to move through the gear 25 and the transmission block 26.

[0050] The water-cooling component includes a water-cooling cavity 27 and a heat sink 28. The water-cooling cavity 27 is disposed in the motor end 21 and is attached to the outer wall of the servo motor 23. One end of the heat sink 28 is connected to the outer wall of the servo motor 23, and the other end is inserted into the water-cooling cavity 27. The heat sink 28 directly contacts the servo motor 23 to conduct heat to the water-cooling cavity. Combined with a full-area water-cooling circuit, it specifically addresses the heat dissipation problem of the motor end 21, preventing motor aging and accuracy drift caused by high temperatures. The water-cooling component is embedded in the motor end 21, without occupying extra space or interfering with the operation of the gear 25 transmission mechanism, balancing structural compactness and functionality. The water-cooling system simultaneously isolates welding radiant heat, extending the service life of the servo motor 23 and transmission components, supporting long-term continuous welding, and improving the overall reliability of the device.

[0051] During operation, the servo motor 23 outputs power, which, through the meshing of gear 25 and transmission block 26, precisely drives the motion end 22 to rotate, thereby driving the robotic arm 1 and the end-effector welding torch 3 to complete multi-posture welding actions. The water-cooling component 1 is adapted to the structure of the motor end 21, including a water-cooling cavity 1 27 and a heat sink 1 28. The water-cooling cavity 1 27 is fitted against the outer wall of the servo motor 23, and one end of the heat sink 1 28 is tightly connected to the outer wall of the servo motor 23, while the other end is inserted into the water-cooling cavity 1 27. The water-cooling cavities 1 27 of adjacent joints 2 are connected through water-cooling pipe 1 7, and simultaneously connected to the water-cooling component 2 of the sensor mounting bracket 4 via water-cooling pipe 2 8, forming a full-area linkage water-cooling loop that continuously removes the heat generated by the operation of the servo motor 23 and welding radiation. The motor end 21 has a built-in temperature detection element that monitors the water temperature and motor temperature in real time.

[0052] Water cooling specifically addresses the heat generation of the core at the motor end (21), while air cooling enhances airflow circulation at the motion end (22), avoiding the limitations of single-mode heat dissipation. The temperature detection of the water cooling system at the motor end (21) is linked with the temperature sensor 214 at the motion end (22), providing real-time temperature data feedback for dynamic adjustment of heat dissipation intensity.

[0053] The moving end 22 has a cavity 29. An air inlet baffle 211 and an air outlet baffle 212 are positioned on the outer shell of the moving end 22 corresponding to the cavity 29. A ventilation hole 210 is provided on the gear 25 or transmission block 26 to connect the air inlet baffle 211 and the air outlet baffle 212. A fan 213 for ventilation and heat dissipation is provided on the air outlet baffle 212. A temperature sensor 214 for monitoring temperature changes inside the moving end 22 is installed inside the cavity 29. Inside the cavity 29 of the moving end 22, the air inlet baffle 211 and the air outlet baffle 212 separate the airflow, while the ventilation hole 210 of the gear 25 or transmission block 26 allows for airflow communication. The fan 213 on the air outlet baffle 212 drives air circulation and ventilation, and the temperature sensor 214 inside the cavity 29 captures real-time temperature changes inside the moving end 22, providing accurate feedback on the heat dissipation status through dual temperature measurement.

[0054] Joint 2, as the core hub for power transmission and attitude adjustment of the device, directly determines welding accuracy, equipment lifespan, and operational stability through its heat dissipation performance. It is a crucial link in ensuring the efficient and reliable operation of the entire device. In this design, joint 2 integrates a servo motor 23 and a gear 25 meshing transmission mechanism. During welding operations, the servo motor 23 operates under high load, generating a large amount of internal heat. This heat, combined with the radiant heat from the welding arc, can easily cause a sudden rise in the internal temperature of joint 2. If heat dissipation is not timely, it will lead to multiple problems.

[0055] As the core power source, the servo motor 23 is susceptible to aging of coil insulation and decay of magnetic properties due to high temperatures. This leads to speed fluctuations and insufficient torque, directly affecting the meshing accuracy of gear 25 and transmission block 26. This causes deviation in the movement of the moving end 22, ultimately resulting in deviation of the welding torch 3's trajectory and quality defects such as poor weld formation and weld misalignment. Furthermore, high temperatures exacerbate the thermal expansion and contraction of gear 25 and transmission block 26, increasing transmission clearance, accelerating wear and deformation, shortening the service life of transmission components, and increasing the frequency of equipment failures and maintenance costs.

[0056] This solution employs a dual water-cooling and air-cooling design, along with comprehensive temperature monitoring, to specifically address the heat dissipation challenges of joint 2. The water-cooling system at the motor end 21 precisely removes heat from the servo motor 23 through full-area water circulation, while the air-cooling system at the motion end 22 enhances internal airflow circulation. Combined with dual temperature monitoring to dynamically adjust heat dissipation intensity, the temperature of each component in joint 2 can be strictly controlled within tolerable limits. Effective heat dissipation at joint 2 maintains the stable performance of the servo motor 23 and the transmission mechanism, preventing precision drift and component aging caused by high temperatures. This ensures the accuracy and consistency of the robotic arm 1's multi-pose welding movements, supports long-term continuous welding operations, and provides stable power to joint 2 for automated welding and precise penetration depth monitoring. It is the core foundation for the entire system to adapt to high-precision, high-intensity welding scenarios.

[0057] The penetration depth sensor 5 is fixed to the sensor mounting bracket 4 via the mounting base 42. The second water-cooling component includes a second water-cooling cavity 43 and a second heat sink 44. The second water-cooling cavity 43 is positioned on the sensor mounting bracket 4 corresponding to the mounting base 42. One end of the second heat sink 44 is connected to the mounting base 42, and the other end is inserted into the second water-cooling cavity 43. The second water-cooling component is embedded in the bracket, precisely matching the mounting base 42 and the sensor. It does not occupy extra space, does not interfere with the sensor's monitoring angle, and balances installation stability and functionality.

[0058] The penetration depth sensor 5 is securely fixed to the sensor mounting bracket 4 via a dedicated mounting base 42 and moves synchronously with the welding torch 3. During welding, it continuously emits laser lines towards the just-cooled weld cross-section, capturing the contour and calculating the penetration depth through an internal camera. The second water-cooling component is precisely fitted to the mounting base 42, and the second water-cooling cavity 43 is located at the position of the bracket corresponding to the mounting base 42. One end of the second heat sink 44 is tightly fitted to the mounting base 42, and the other end is inserted into the second water-cooling cavity 43, forming an efficient heat conduction path. The second water-cooling cavity 43 is connected to the first water-cooling cavity 27 of the motor end 21 of the joint 2 via the second water-cooling pipe 8, and is connected to the full-area water circulation loop. It works in conjunction with the water-cooling system of the joint 2 to continuously remove the heat generated by the penetration depth sensor 5 during operation and welding radiation. At the same time, the vision sensor probe 6 on the bracket can also be cooled synchronously by relying on the same water-cooling loop to achieve precise cooling of the sensor cluster.

[0059] like Figure 3As shown, both the weld penetration sensor 5 and the vision sensor probe 6 are equipped with transparent anti-spatter protective covers 41. The weld penetration sensor 5 is fixed to the sensor mounting bracket 4 by the mounting base 42 and is arranged side by side with the vision sensor probe 6. Both are equipped with transparent anti-spatter protective covers 41 to prevent welding spatter and dust from directly corroding the probe body and the acquisition window.

[0060] The sensor mounting bracket 4 is also equipped with an air cooling component 46, which is tilted at an angle to the splash guard 41 to clean the dust on the splash guard 41 and reduce its internal temperature.

[0061] The air-cooling component 46 is mounted on the sensor mounting bracket 4 via a nozzle bracket 45 and connected to an air duct 47 that provides dry compressed air. The air-cooling component 46 is fixed to the bracket via the nozzle bracket 45. The air-cooling component 46 is connected to the air duct 47 that delivers dry compressed air and is precisely aligned at an angle with the anti-splash protective covers 41 of the two sensors, with continuous airflow throughout the welding process. The airflow serves two purposes: firstly, it cleans the surface of the protective covers of dust and splash residue, ensuring the transparency of the windows; secondly, it cools the protective covers and internal sensors, forming a synergistic heat dissipation system with the water-cooling component 2 inside the bracket. Simultaneously, the water-cooling component 2 is connected to a full-area water circulation loop via heat sink 2 44 and water-cooling cavity 2 43, complementing the air cooling to achieve multi-dimensional cooling of the sensors.

[0062] The air-cooling component of this device uses an industrial-grade anti-spatter air-cooling nozzle assembly, which is suitable for high-temperature welding conditions. The specific model is a side-blowing high-pressure air-cooling nozzle assembly with a rated air supply pressure of 0.4-0.6MPa. It is compatible with dry compressed air sources. During operation, air is continuously supplied from an external air source and delivered to the air-cooling component 46 through the air guide pipe 47. Dry air is continuously sprayed onto the anti-spatter protective cover 41 of the sensor at an angle of 30-45°, simultaneously completing the dust removal and surface cooling of the protective cover. Welding start and stop are linked with the air-cooling component 46, with pre-blowing before welding, continuous operation during welding, and delayed shutdown after welding, ensuring that there are no dead corners in the protection and cleaning.

[0063] The pipeline adopts an anti-winding design. The air guide tube 47 is made of flexible wear-resistant corrugated pipe, which is synchronously linked with the sensor mounting bracket 4 and the welding gun 3. The redundant length is reserved and it is fixed to the side wall of the robotic arm 1 with buckles. Water cooling pipe 7 and water cooling pipe 8 are both made of high temperature resistant and flame retardant flexible water cooling pipe. Water cooling pipe 7 runs along the outside of the joint 2 between adjacent joints 2 and is equipped with a rotary joint. Water cooling pipe 8 connects the joint 2 and the sensor bracket 4 and is fixed with segmented buckles to adapt to the multi-posture movement of the robotic arm 1 and avoid pipeline entanglement and interference from the source.

[0064] The water circulation is powered by an external industrial-grade micro circulating water pump with a rated head of 8-12m, which can stably drive the circulating water flow. The circulating water is deionized pure water to avoid scaling and blockage in the pipes. After being pressurized by the pump, the circulating water enters the water-cooling pipe 7 and flows through the water-cooling chamber 27 of each joint 2 to dissipate heat from the servo motor 23. Then, it flows through the water-cooling pipe 8 into the water-cooling chamber 43 of the sensor bracket 4 to dissipate heat from the sensor. After dissipating heat from the sensor, it flows back to the water storage tank, forming a closed-loop water circulation to ensure continuous and stable heat dissipation, which is suitable for long-term continuous welding requirements.

[0065] The penetration depth sensor 5 and the vision sensor probe 6 are the core components of the six-axis industrial robot automatic welding device to achieve accurate monitoring and stable welding. Their operating status directly determines the welding quality control effect. Probe protection, dust removal and heat dissipation are the three key factors to ensure the long-term accurate operation of the sensor. They are suitable for the harsh working conditions of high temperature, a lot of spatter and high dust in welding scenarios, and none of them can be omitted.

[0066] The core value of probe protection lies in constructing a physical protective barrier. High-temperature metal spatter and welding fumes generated during welding can directly impact and adhere to the probe's acquisition window and body. This not only scratches the transparent window and obstructs the acquisition field of view, leading to laser transmission attenuation and visual imaging distortion, but also may cause permanent damage to the sensor due to the high-temperature spatter burning probe components. In this solution, the transparent anti-splash protective cover 41 provides direct protection for the probe, effectively isolating it from spatter erosion and dust adhesion, preventing damage to the probe structure, and maintaining the transparency of the acquisition window—a fundamental prerequisite for the normal operation of the sensor.

[0067] Dust removal is essential for ensuring monitoring accuracy. Even with a protective cover, welding dust and tiny spatter can still adhere to its surface. If not cleaned promptly, these can gradually obstruct laser and visual signals, leading to deviations in penetration depth calculations, misalignment of weld seams, and ultimately, welding defects such as incomplete fusion and weld misalignment. The air-cooled assembly's 46-degree inclined airflow precisely cleans the protective cover, removing surface impurities in real time, maintaining a clear viewing window, ensuring the authenticity and accuracy of sensor data, and preventing signal interference from affecting quality control precision.

[0068] Heat dissipation is crucial for maintaining sensor stability and lifespan. The combined heat from the welding arc and the sensor's own operation can easily lead to high-temperature aging of internal components, accuracy drift, and even chip failure and signal transmission malfunction. This solution utilizes a combination of air cooling and water cooling. Air cooling lowers the temperature of the protective cover and sensor surface, while water cooling deeply conducts heat to the core components. This keeps the sensor temperature strictly controlled within its tolerance range, preventing a decrease in monitoring accuracy due to high temperatures, slowing down component aging, extending sensor lifespan, providing stable support for long-term continuous welding operations, and ensuring the closed-loop control capability of the entire welding system.

[0069] In this invention, the core of the solution is a dual cooling system combining water and air cooling at joint 2. A water-cooled component at the motor end 21 is integrated with the servo motor 23 for efficient cooling, while air cooling at the motion end 22 provides coordinated temperature control. Combined with a full-area water circulation loop, this completely solves the problems of accuracy drift and component aging caused by high temperatures. The sensor integrates a dedicated bracket, and a splash guard 41 is paired with an inclined air-cooling component 46 to achieve physical protection, real-time dust removal, and surface heat dissipation. The water-cooling component 2 simultaneously enhances core cooling, ensuring stable monitoring accuracy. The entire solution offers significant advantages, achieving multiple benefits: both welding accuracy and quality meet standards; precise transmission and real-time penetration monitoring avoid various defects; equipment stability is greatly improved; multi-dimensional heat dissipation and protection extend the lifespan of core components; it is suitable for long-term continuous operation; automated and collaborative design reduces manual intervention, balancing efficiency and reliability. It can accurately meet the welding needs under high-precision and harsh working conditions, and its overall practicality far exceeds that of traditional devices.

[0070] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A six-axis industrial robot automatic welding system, characterized in that: include: The automatic welding module uses a six-axis robot body as the core carrier, and coordinates the six joint servo drive based on vision sensor probes to link the welding gun to achieve automated welding. It has intelligent path planning and automatically generates the optimal welding trajectory. The weld penetration monitoring module emits a laser line through a weld penetration sensor, which illuminates the cross-section of the weld that has just cooled. The camera inside the laser weld penetration sensor captures the deformation profile of the laser line on the weld cross-section, measures the weld reinforcement and weld width, calculates the weld penetration based on the calibration model, and monitors it in real time. The heat dissipation module uses air cooling or water cooling to keep the temperature of the vision sensor probe, the depth sensor, and the servo motor in the joint within a tolerable range.

2. A six-axis industrial robot automatic welding device, comprising multiple robotic arms (1) connected by joints (2), and a welding torch (3) connected to the end of each robotic arm (1), characterized in that: The welding torch (3) is equipped with a sensor mounting bracket (4), and the sensor mounting bracket (4) is provided with a penetration depth sensor (5) and a vision sensor probe (6). Multiple joints (2) are equipped with water-cooled component 1 inside, and the sensor mounting bracket (4) is equipped with water-cooled component 2 inside. Two adjacent water-cooled components 1 are connected by water-cooled pipe 1 (7), and the water-cooled component 1 and water-cooled component 2 are connected by water-cooled pipe 2 (8).

3. The six-axis industrial robot automatic welding device according to claim 2, characterized in that: The joint (2) includes a motor end (21) and a moving end (22). A servo motor (23) is installed inside the motor end (21). A gear (25) is connected to the shaft (24) of the servo motor (23). A transmission block (26) meshing with the gear (25) is provided inside the moving end (22). The servo motor (23) is used to drive the moving end (22) to move through the gear (25) and the transmission block (26). The water-cooling assembly includes a water-cooling cavity (27) and a heat sink (28). The water-cooling cavity (27) is disposed in the motor end (21) and is attached to the outer wall of the servo motor (23). One end of the heat sink (28) is connected to the outer wall of the servo motor (23), and the other end is inserted into the water-cooling cavity (27).

4. The six-axis industrial robot automatic welding device according to claim 3, characterized in that: The moving end (22) is provided with a cavity (29). An air inlet baffle (211) and an air outlet baffle (212) are provided on the outer shell of the moving end (22) at the position corresponding to the cavity (29). A ventilation hole (210) is provided on the gear (25) or transmission block (26) to connect the air inlet baffle (211) and the air outlet baffle (212).

5. The six-axis industrial robot automatic welding device according to claim 4, characterized in that: The air outlet baffle (212) is equipped with a fan (213) for ventilation and heat dissipation.

6. The six-axis industrial robot automatic welding device according to claim 4, characterized in that: A temperature sensor (214) for monitoring the temperature change inside the moving end (22) is installed inside the cavity (29).

7. The six-axis industrial robot automatic welding device according to claim 2, characterized in that: Both the melt depth sensor (5) and the vision sensor probe (6) are equipped with transparent anti-splash protective covers (41).

8. The six-axis industrial robot automatic welding device according to claim 7, characterized in that: The melt depth sensor (5) is fixed on the sensor mounting bracket (4) by the mounting base (42); The second water-cooling component includes a second water-cooling cavity (43) and a second heat sink (44). The second water-cooling cavity (43) is located at the position of the sensor mounting bracket (4) corresponding to the mounting base (42). One end of the second heat sink (44) is connected to the mounting base (42), and the other end is inserted into the second water-cooling cavity (43).

9. The six-axis industrial robot automatic welding device according to claim 8, characterized in that: The sensor mounting bracket (4) is also provided with an air cooling component (46), which is tilted at an angle to the splash guard (41) to clean the dust on the splash guard (41) and reduce its internal temperature.

10. The six-axis industrial robot automatic welding device according to claim 9, characterized in that: The air-cooling assembly (46) is mounted on the sensor mounting bracket (4) via the nozzle bracket (45) and connected to the air duct (47) that provides dry compressed air.

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