Automatic welding device for sanitation tank welding

Abstract

The application belongs to the technical field of welding equipment, and particularly relates to an automatic welding device for sanitation box welding, which comprises a welding device body; a PLC control system, a power management unit and a welding process database are integrated in the welding device body; an auxiliary positioning mechanism is symmetrically installed on the inner side of the welding device body; a welding mechanical arm is installed on the inner side top of the welding device body; the welding mechanical arm adopts six-degree-of-freedom joints, and a welding torch is detachably installed at the tail end; the software and hardware are combined with chopper control technology to reduce the welding spatter amount. The plate parameter identification module and the arc striking optimization module are additionally arranged, visual identification and thickness detection are combined, plate parameters are accurately obtained, the arc striking wire back-pulling technology and the arc striking parameter optimization are matched, the weld flatness in the arc striking stage is ensured, and the problems of uneven weld beginning and arc striking defects are completely solved.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to an automatic welding device for welding sanitation boxes. Background Technology

[0002] Sanitation bins are an important component of urban environmental sanitation facilities, and their manufacturing quality directly affects their service life and the aesthetics of the urban environment. Welding is a crucial step in the production of sanitation bins, as its quality directly impacts the overall strength, sealing performance, and appearance of the product. With the development of automation technology, automatic welding equipment is increasingly being used in sanitation bin production, gradually replacing traditional manual welding to improve production efficiency and weld consistency.

[0003] Currently, welding equipment still has some shortcomings when welding sanitation boxes: First, the calculation of the box's dimensions and thickness is not precise enough, and the distance control during the arc-starting stage of the welding torch lacks dynamic adjustment, which easily leads to unevenness and arc-starting defects in the initial section of the weld, resulting in insufficient welding strength and reduced service life. Second, the moving speed of the welding torch and the welding parameters lack a linkage and adaptive adjustment mechanism. Too fast a speed will lead to insufficient welding and insufficient penetration, while too slow a speed may cause over-welding and excessive thermal deformation, resulting in welding defects and affecting welding quality. Third, the positioning mechanism of existing equipment is mostly designed with fixed dimensions, which cannot flexibly adapt to sanitation box plates of different specifications and shapes, resulting in insufficient positioning accuracy and easy welding misalignment. Summary of the Invention

[0004] This invention addresses the shortcomings of existing welding devices when welding sanitation boxes, and provides an automatic welding device for welding sanitation boxes. Specifically, it solves the problems of low accuracy in recognizing the size of the sanitation box and the thickness of the sheet metal, unreasonable control of the distance during the arc initiation stage of the welding torch, lack of linkage and adaptive adjustment between the welding torch movement speed and welding parameters, poor adaptability of the auxiliary positioning mechanism, inability to flexibly adapt to different specifications of sanitation box sheet metal, insufficient positioning accuracy, and easy welding misalignment.

[0005] To address the aforementioned technical problems, this invention provides an automatic welding device for welding sanitation boxes, comprising a welding device body, a welding robotic arm, an auxiliary positioning mechanism, moving parts, a parameter adaptive adjustment module, a welding monitoring module, and a plate parameter identification module. The welding device body integrates a PLC control system, a power management unit, and a welding process database. The welding process database pre-stores welding parameters (current, voltage, wire feed speed) for sanitation box plates of different materials (carbon steel, stainless steel) and thicknesses, and supports custom parameter input and updates. The auxiliary positioning mechanism is symmetrically installed on the inner side of the welding device body, and a welding robotic arm is installed on the top inner side of the welding device body. The welding robotic arm employs six degrees of freedom joints, with a detachable welding torch at its end. The welding torch uses an ultra-low spatter gas shielded welding structure, combined with hardware and software chopper control technology to reduce welding spatter. The welding robotic arm is electrically connected to the control end of the welding device body, receiving control commands to execute welding actions. The auxiliary positioning mechanism includes an adjustable positioning clamp, a displacement adjustment component, and a pressure sensor. The adjustable positioning clamp is pneumatically controlled and can flexibly adjust the clamping width and angle according to the size of the plate. It is suitable for the splicing and positioning of the side plate and bottom plate of the sanitation box, and the side plate and side plate. The displacement adjustment component is electrically connected to the main body of the welding device and can realize the horizontal and vertical displacement adjustment of the positioning clamp. The pressure sensor is embedded in the inside of the adjustable positioning clamp to detect the clamping pressure and avoid excessive clamping that causes plate deformation or excessive clamping that causes welding displacement. The auxiliary positioning mechanism positions and holds the box plate to be welded with a positioning accuracy of 0.05mm. The moving component includes a distance sensor, an electrically driven moving component, and a track assembly. The distance sensor is installed at the end of the welding torch and is used to detect the distance between the welding torch head and the box plate in real time with a detection accuracy of 0.01mm. The electrically driven moving component is driven by a servo motor and is slidably connected to the track assembly, which can drive the welding robot arm to move along the track to realize large-scale welding operations. The moving component is electrically connected to the control end of the main body of the welding device and receives control commands to adjust the moving trajectory and speed. The plate parameter recognition module includes a visual recognition camera and a thickness detection sensor, which are installed on the side of the welding robotic arm. It is used to identify the size, shape and thickness of the plate to be welded in real time and transmit the recognition data to the PLC control system of the main body of the welding device. The control system combines the welding process database to automatically match the optimal welding parameters. The parameter adaptive adjustment module is electrically connected to the main body of the welding device, the welding robotic arm, and the moving parts. It is used to adjust the welding torch moving speed, welding current, voltage, and wire feeding speed in real time according to the plate data transmitted by the plate parameter identification module and the distance data detected by the distance sensor. This achieves adaptive matching between the welding parameters and the plate characteristics and welding position. The welding torch moving speed adjustment range is 0.5-5m / min, the welding current adjustment range is 50-350A, and the voltage adjustment range is 10-40V. The welding monitoring module includes a weld formation monitoring camera and a temperature sensor. The weld formation monitoring camera is used to capture the weld formation status in real time with a resolution of 1080P. It can identify defects such as weld width deviation, undercut, and weld beads. The temperature sensor is an infrared temperature sensor with a detection range of 0-1000℃ and a detection accuracy of 5℃. It is used to detect the temperature of the welding area. Both transmit the monitoring data to the PLC control system of the main body of the welding device. When the weld width deviation exceeds 0.5mm, the temperature exceeds 800℃, or a welding defect occurs, the control system automatically triggers a parameter adjustment command. The welding parameters are corrected through the parameter adaptive adjustment module, or welding is paused and an audible and visual alarm is issued.

[0006] Furthermore, the main body of the welding device also integrates an arc ignition optimization module, which, in the initial stage of welding, controls the welding torch to perform an adaptive arc ignition wire retraction action based on the plate thickness data obtained by the plate parameter identification module, and optimizes the current and voltage parameters in the arc ignition stage to avoid defects such as uneven welds and incomplete penetration in the arc ignition stage, thereby improving the arc ignition success rate.

[0007] Furthermore, the PLC control system of the main body of the welding device adopts a three-level main power topology, with an inverter frequency of up to 110KHz, low sampling delay, and higher control precision, ensuring the stability of the welding process.

[0008] Preferably, the welding torch connector can be replaced with different types of welding nozzles according to welding requirements, adapting to different types of sanitation box welding requirements such as fillet welds and butt welds, and supports multiple welding processes such as critical pulse welding and DC high-speed welding. Among them, the critical pulse welding mode can improve the welding speed compared with the standard pulse.

[0009] Furthermore, the main body of the welding device is equipped with a touch operation panel and a remote communication interface, which can realize local manual operation, parameter setting and remote monitoring and control, making it convenient for operators to keep track of the welding status in real time, and supports the storage and export of welding data, which facilitates production traceability.

[0010] Optionally, the adjustable positioning clamp of the auxiliary positioning mechanism is provided with an anti-scratch pad on the inner side to avoid scratching the surface of the sanitation box material during clamping and to ensure the appearance quality of the product.

[0011] Beneficial effects This invention adds a plate parameter identification module and an arc ignition optimization module. By combining visual recognition with thickness detection, it accurately obtains plate parameters. Combined with arc ignition wire retraction technology and arc ignition parameter optimization, it ensures a smooth weld during the arc ignition stage, completely solving the problems of uneven weld start and arc ignition defects. At the same time, it combines ultra-low spatter welding technology to reduce welding spatter, reduce subsequent grinding processes, and improve production efficiency.

[0012] In addition, an adaptive parameter adjustment module is added to realize the linkage adaptive adjustment of welding torch movement speed and welding parameters. The parameters are optimized in real time according to the characteristics of the plate and the welding position, avoiding insufficient welding caused by excessive speed and over-welding caused by excessive speed, which greatly reduces the welding defect rate and improves the welding qualification rate.

[0013] In addition, an auxiliary positioning mechanism is set up and an adjustable positioning clamp and displacement adjustment component are used, along with a pressure sensor. At the same time, the clamping pressure is tested in conjunction with the sensors on the telescopic rod and the bottom plate. This can not only flexibly adapt to sanitation box plates of different specifications and shapes, but also accurately control the clamping pressure, avoid plate deformation and welding displacement, improve positioning accuracy, and further improve welding accuracy.

[0014] In addition, the welding monitoring module enables real-time monitoring and feedback correction of the welding process. It can promptly detect problems such as abnormal weld formation and temperature, and automatically trigger parameter adjustments or alarms to prevent the expansion of welding defects and improve the stability of welding quality. At the same time, welding data can be stored and exported, facilitating production traceability and process optimization. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments will be briefly described below.

[0016] The accompanying drawings described below are only related to some embodiments of the invention and are not intended to limit the invention.

[0017] In the attached diagram: Figure 1 This is a schematic diagram of the overall structure of the present invention from the left front view.

[0018] Figure 2 This is a schematic diagram of the welding device of the present invention, which lacks a top plate and a back plate.

[0019] Figure 3 This is a schematic diagram of the welding robotic arm of the present invention.

[0020] Figure 4 This is a schematic diagram of the welding torch of the present invention.

[0021] Figure 5 This is the present invention. Figure 4 A magnified structural diagram of point A in the middle.

[0022] Figure 6 This is a schematic diagram of the structure of the suspension rail and the telescopic rod of the present invention.

[0023] Figure 7 This is a schematic diagram of the auxiliary positioning mechanism of the present invention.

[0024] Figure 8 This is a structural schematic diagram of the welding monitoring module of the present invention.

[0025] Figure 9 This is a logic block diagram of the control system of the present invention.

[0026] Figure 10 This is a schematic diagram of the structure of the card plate parameter recognition module of the present invention.

[0027] List of reference numerals in the attached diagram: 1. Welding device main body; 11. Hanging rail; 12. Hanging telescopic rod; 13. Support plate; 14. Right-angle connecting plate; 1401. Inner sliding groove plate; 2. Welding robotic arm; 21. Welding torch connector; 2101. Pull plate; 2102. Clamping plate; 21011. Connecting rod; 21012. Clamping cone block; 3. Auxiliary positioning mechanism; 31. Adjustable positioning fixture; 3101. Bidirectional telescopic connecting rod; 32. Displacement adjustment component; 3201. Servo motor; 3202. Double threaded rod; 33. Pressure sensor; 4. Moving parts; 41. Distance sensor; 42. Electrically driven moving parts; 43. Track assembly; 5. Parameter adaptive adjustment module; 6. Welding monitoring module; 61. Weld formation monitoring camera; 62. Temperature sensor; 7. Plate parameter recognition module; 71. Visual recognition camera; 72. Thickness detection sensor; 8. Arc ignition optimization module. Detailed Implementation

[0028] To make the objectives, solutions, and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Unless otherwise stated, the terms used herein have their ordinary meanings in the art. The same reference numerals in the drawings represent the same parts.

[0029] Example: Please refer to Figures 1 to 10 As shown: like Figure 1-10As shown, an automatic welding device for welding sanitation boxes includes a welding device body 1, a welding robotic arm 2, an auxiliary positioning mechanism 3, a moving part 4, a parameter adaptive adjustment module 5, a welding monitoring module 6, and a plate parameter identification module 7. The welding device body 1 is the core control center of the entire device, integrating a PLC control system, a power management unit, and a welding process database. The welding process database pre-stores welding parameters for two commonly used sanitation box plates: carbon steel and stainless steel. The welding current for carbon steel plates is 80-200A, and the voltage is 15-25V. The wire feeding speed is 3-8m / min; the welding current for stainless steel plates is 60-180A, the voltage is 12-22V, and the wire feeding speed is 2-6m / min. It also supports custom parameter input and updates. The PLC control system adopts a three-level main power topology structure with an inverter frequency of up to 110KHz, low sampling delay, and high control accuracy. The base plate of the welding device body 1 is equipped with a track assembly 43, on which two sets of symmetrical auxiliary positioning mechanisms 3 are slidably installed. The welding robotic arm 2 is installed on the slide rail of the base plate of the welding device body 1.The welding robotic arm 2 is a six-axis robotic arm capable of 360-degree omnidirectional welding operations. The welding robotic arm 2 is electrically connected to the control end of the welding device body 1 via a cable, receiving control commands to execute welding actions. The end of the welding robotic arm 2 is detachably connected to a welding torch connector 21 via a threaded connection. The welding torch connector 21 adopts an ultra-low spatter gas shielded welding structure, utilizing chopper control technology in conjunction with hardware and software to reduce welding spatter by more than 90%. Furthermore, the end of the welding torch connector 21 is equipped with a locking plate for fastening... A pull plate 2101 is slidably engaged inside the plate. Below the pull plate 2101 and inside the buckle plate, a clamping plate 2102 is engaged. The bottom of the pull plate 2101 is connected to the bottom surface of the sliding groove inside the buckle plate via a built-in spring telescopic rod. Connecting rods 21011 are rotatably connected to both sides of the pull plate 2101 via shafts. The ends of the connecting rods 21011 are rotatably connected to a cone block 21012 via shafts. The cone block 21012 is engaged at the end of the welding robotic arm 2. After removing the clamping plate 2102, it is pulled downwards. Pull plate 2101 synchronously drives connecting rod 21011 to move downward. Pull plate 2101 compresses the built-in spring telescopic rod and pulls connecting rod 21011 to rotate. Connecting rod 21011 drives the locking cone block 21012 to slide inward. After the locking cone block 21012 is retracted, the welding torch connector 21 can be pulled downward to disengage from the end of welding robotic arm 2, thus achieving disassembly. When installing welding torch connector 21, keep pull plate 2101 in the lowest position first, lock it to the end of welding robotic arm 2, and then release pull plate. 2101, the built-in spring telescopic rod pushes the pull plate 2101 upward, and through the connecting rod 21011 pushes the locking cone block 21012 to slide outward. After the locking cone block 21012 is engaged with the end of the welding robot arm 2, the locking plate 2102 is engaged with the lower part of the pull plate 2101, restricting the pull plate 2101 from moving downward, thus completing the installation of the welding gun connector 21. The sleeve of the welding gun is connected to the inside of the welding gun connector 21 through the threaded connection, thus completing the assembly of the welding gun and at the same time protecting the conductive rod used for welding. The auxiliary positioning mechanism 3 includes an adjustable positioning clamp 31, a displacement adjustment component 32, and a pressure sensor 33. The bottom of the adjustable positioning clamp 31 is pneumatically controlled, and the pneumatically controlled moving block is slidably mounted on the guide rail on the top surface of the bottom plate of the welding device body 1. The adjustable positioning clamp 31 is adapted for the splicing and positioning of the side plate and the bottom plate of the sanitation box, and the side plate and the side plate. A bidirectional telescopic connecting rod 3101 connects the left and right adjustable positioning clamps 31. The displacement adjustment component 32 consists of a servo motor 3201 and a double threaded rod 3202, which is electrically connected to the welding device body 1. The double threaded rod 3202 is connected to the right threaded hole of the adjustable positioning clamp 31 through a thread. The front and rear positions of the adjustable positioning clamp 31 can be adjusted by the displacement adjustment component 32. The left and right sides of the adjustable positioning clamp 31 are provided with protruding rectangular plates. The bottom of the two corresponding adjustable positioning clamps 31 is fixedly connected with a moving plate. The top surface of the moving plate is fixedly provided with a locking strip. The locking strip is installed on the adjustable positioning clamp 31. Above the rectangular plates on both sides of the positioning clamp 31, the axial rotation of the adjustable positioning clamp 31 is restricted by the rectangular plates and the locking strip, so that the adjustable positioning clamp 31 can only move back and forth, realizing back and forth adjustment, and clamping and fixing the bottom plate and side plate of the sanitation box placed between the adjustable positioning clamps 31. The bottom of the moving plate is driven by either a cylinder or an electric slider to realize the left and right displacement adjustment of the adjustable positioning clamp 31 with an adjustment accuracy of 0.01mm. The pressure sensor 33 is embedded inside the adjustable positioning clamp 31, with a detection range of 0-500N, and is used to detect the clamping pressure. When the pressure exceeds 300N or is lower than 100N, a feedback signal is sent to the control system, and the control system adjusts the clamping pressure to avoid the plate deformation caused by excessive clamping and the welding displacement caused by excessive clamping. The auxiliary positioning mechanism 3 positions and holds the box plate to be welded with a positioning accuracy of 0.05mm. The inner side of the adjustable positioning clamp 31 is provided with a rubber anti-scratch pad to avoid scratching the surface of the plate. The moving part 4 includes a distance sensor 41, an electric drive moving part 42, and a track assembly 43. The distance sensor 41 is a laser distance sensor, which is installed at the end of the welding torch connector 21. It is used to detect the distance between the welding torch head and the box plate in real time. The detection accuracy reaches 0.01mm and the detection range is 5-100mm. The electric drive moving part 42 is slidably connected to the track assembly 43. The track assembly 43 is fixedly installed on the top surface of the bottom plate of the welding device body 1. The track assembly 43 is 3m long and can drive the welding robot arm 2 to move along the track to realize large-scale welding operations. The moving part 4 is electrically connected to the control end of the welding device body 1 and receives control commands to adjust the moving trajectory and speed. The welding torch moving speed adjustment range is 0.5-5m / min. The plate parameter recognition module 7 includes a visual recognition camera 71 and a thickness detection sensor 72. Both the visual recognition camera 71 and the thickness detection sensor 72 are installed on the side of the welding torch connector 21. The visual recognition camera 71 is used to identify the size and shape of the plate to be welded in real time with an accuracy of 0.1mm. The thickness detection sensor 72 is an ultrasonic thickness sensor with a detection range of 1-20mm and an accuracy of 0.02mm. Both transmit the recognition data to the PLC control system of the welding device body 1. The control system, combined with the welding process database, automatically matches the optimal welding parameters. The parameter adaptive adjustment module 5 is electrically connected to the main body 1 of the welding device, the welding robotic arm 2, and the moving part 4. It is used to adjust the welding torch moving speed, welding current, voltage, and wire feeding speed in real time according to the plate data transmitted by the plate parameter identification module 7 and the distance data detected by the distance sensor 41, so as to achieve adaptive matching between welding parameters and plate characteristics and welding position. For example, when the plate thickness is detected to increase by 1 mm, the control system automatically increases the welding current by 10-15A, increases the voltage by 1-2V, and reduces the moving speed of the welding torch 21 by 0.3-0.5 m / min. When the distance between the welding torch and the plate is detected to deviate from the optimal distance by 8 mm, the position of the welding robotic arm 2 is automatically adjusted to ensure welding stability.

[0030] The main body 1 of the welding device also integrates an arc ignition optimization module 8, which, in the initial stage of welding, controls the welding torch 21 to perform an adaptive arc ignition wire retraction action based on the plate thickness data obtained by the plate parameter identification module 7. The retraction speed is 5-10 mm / s and the retraction distance is 2-3 mm. At the same time, it optimizes the current and voltage parameters in the arc ignition stage. The arc ignition current is 10-20A higher than the normal welding current, and the arc ignition voltage is 2-3V higher than the normal welding voltage. After 0.5-1s, the parameters return to normal, avoiding defects such as uneven weld and incomplete penetration in the arc ignition stage, and greatly improving the arc ignition success rate.

[0031] In this embodiment, the welding torch connector 21 can be replaced with fillet weld nozzles and butt weld nozzles according to welding requirements, adapting to the welding requirements of different types of welds in sanitation boxes, and supporting multiple welding processes such as critical pulse welding and DC high-speed welding. Among them, the critical pulse welding mode can increase the welding speed by more than 20% compared with the standard pulse.

[0032] In this embodiment, the main body 1 of the welding device is equipped with a 10-inch touch operation panel and an Ethernet remote communication interface, which can realize local manual operation, parameter setting and remote monitoring and control, so that the operator can keep track of the welding status in real time. It also supports the storage and export of welding data, such as welding parameters, welding time, welding defect records, etc., with a storage capacity of up to 10,000 records, which is convenient for production traceability. The top plate of the main body 1 of the welding device is fixedly welded with a hanging rail 11. An electric drive slider is slidably engaged on the hanging rail 11. A telescopic rod 12 is installed at the bottom of the electric drive slider. The lowest height of the telescopic rod 12 after being retracted is higher than the maximum height of the sanitation box to be welded. The telescopic rod 12 is electrically connected to the PLC control system, and a stop plate 13 is installed at the end of the telescopic rod 12. A sensor is embedded in the stop plate 13. The control system starts the movement of the electric drive slider. After adjusting the position, it cooperates with the adjustable positioning clamp 31 to clamp the plate to be welded. The clamping plate 13 is used to prevent the plate from tipping over. The sensor embedded in the plate 13 works with the pressure sensor 33 to accurately detect the clamping pressure. A right-angle connecting plate 14 is installed on the bottom plate of the main body 1 of the welding device and on the electric drive moving part 42. An inner sliding plate 1401 is fixedly connected to the upright plate of the right-angle connecting plate 14. A connecting block is slidably engaged inside the inner sliding plate 1401. Telescopic rods are installed on the bottom and inner side of the connecting block. The end of the telescopic rod on the inner side is engaged with the welding monitoring module 6 by a hexagonal screw. The telescopic rods are electrically connected to the PLC control system. When the telescopic rod is activated by the control system, the position and height of the welding monitoring module 6 can be pushed. At the same time, it can match the speed of the welding gun movement to achieve real-time monitoring. By engaging with the hexagonal screw, the orientation of the camera and sensor of the welding monitoring module 6 can be pre-adjusted according to the size of the sanitation box to be welded, so as to ensure that the weld can be tracked and monitored in real time.

[0033] In this embodiment, the welding monitoring module 6 includes a weld formation monitoring camera 61 and a temperature sensor 62. The weld formation monitoring camera 61 is used to capture the weld formation status in real time with a resolution of 1080P. It can identify defects such as weld width deviation, undercut, and weld beads. The temperature sensor 62 is an infrared temperature sensor with a detection range of 0-1000℃ and a detection accuracy of 5℃. It is used to detect the temperature of the welding area. Both transmit the monitoring data to the PLC control system of the welding device body 1. When the weld width deviation exceeds 0.5mm, the temperature exceeds 800℃, or a welding defect occurs, the control system automatically triggers a parameter adjustment command. The welding parameters are corrected through the parameter adaptive adjustment module 5, or welding is paused and an audible and visual alarm is issued.

[0034] The working process of this embodiment is as follows: First, the sanitation box plate to be welded is placed on the auxiliary positioning mechanism 3 via the conveying mechanism of the previous process. The device is started via the touch operation panel. The visual recognition camera 71 and the thickness detection sensor 72 of the plate parameter recognition module 7 identify the size, shape and thickness of the plate respectively, and transmit the data to the PLC control system of the welding device body 1. According to the identified plate parameters, the control system controls the displacement adjustment component 32 of the auxiliary positioning mechanism 3 to adjust the position of the adjustable positioning clamp 31. Then, the pneumatically controlled moving block slides and drives the adjustable positioning clamp 31 to clamp the plate. At the same time, the electric drive slider is activated to move the lifting telescopic rod 12. The support plate 13 and the pressure sensor 33 detect the clamping pressure in real time to ensure that the pressure is between 100-300N to avoid plate deformation or displacement. Then, parameter matching is performed. The control system, combined with the welding process database, automatically matches the optimal welding parameters based on the plate material and thickness (e.g., for a carbon steel base plate thickness of 5mm, matching welding current of 120A, voltage of 18V, wire feed speed of 5m / min, and welding torch moving speed of 2m / min), and transmits the parameters to the parameter adaptive adjustment module 5. The control system controls the welding robotic arm 2 to move the welding torch connector 21 to the welding start position. The distance sensor 41 detects the distance between the welding torch head and the plate and adjusts it to the optimal distance of 8mm. The arc ignition optimization module 8 is activated, controlling the welding torch to perform the wire retraction action while optimizing the arc ignition parameters to complete the arc ignition. Subsequently, parameter adaptive adjustment is performed. The adjustment module 5 adjusts the welding torch movement speed and welding parameters based on real-time detected plate data and distance data, and the welding robotic arm 2 performs welding operations according to the preset trajectory. The weld formation monitoring camera 61 and temperature sensor 62 of the welding monitoring module 6 monitor the welding status in real time and transmit the data to the control system. If uneven weld formation, abnormal temperature, or welding defects are detected, the control system automatically adjusts the welding parameters or suspends welding and issues an alarm. After the welding operation is completed, the welding robotic arm 2 resets, the auxiliary positioning mechanism 3 releases the clamp, and the welded plate is removed using the external conveying mechanism. The control system stores the welding data for this operation, which can be exported or viewed remotely via the touch panel.

[0035] In this embodiment, the automatic welding device achieves automated, efficient, and precise welding of sanitation boxes through the organic integration of various modules, improving the welding qualification rate and significantly increasing welding efficiency compared to existing devices. It can also reduce production costs and the labor intensity of operators, effectively solving the welding defect problems existing in the prior art and adapting to the production needs of sanitation boxes.

[0036] In this invention, unless otherwise explicitly specified and limited, the terms installation, connection, linking, fixing, etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0037] Obviously, the embodiments described above are merely some embodiments of the present invention, not all embodiments. The accompanying drawings show preferred embodiments of the present invention, but do not limit the patent scope of the present invention. The present invention can be implemented in many different forms; rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing specific embodiments, or make equivalent substitutions for some of the technical features. Any equivalent structures made using the content of this specification and drawings, directly or indirectly applied to other related technical fields, are similarly within the patent protection scope of this invention.

Claims

1. An automatic welding device for welding sanitation boxes, comprising a welding device body (1), a welding robotic arm (2), an auxiliary positioning mechanism (3), a moving component (4), a parameter adaptive adjustment module (5), a welding monitoring module (6), and a plate parameter identification module (7); characterized in that, The welding device body (1) integrates a PLC control system, a power management unit and a welding process database. A track assembly (43) is installed on the bottom plate of the welding device body (1). The welding device body (1) integrates an arc starting optimization module (8). Two sets of symmetrical auxiliary positioning mechanisms (3) are slidably installed on the track assembly (43). A welding robot arm (2) is installed on the track assembly (43). A detachable welding torch connector (21) is installed at the end of the welding robot arm (2). The welding torch is installed at the end of the welding torch connector (21) by thread. The welding torch adopts an ultra-low spatter gas shielded welding structure. The auxiliary positioning mechanism (3) includes an adjustable positioning fixture (31), a displacement adjustment component (32), and a pressure sensor (33). The bottom of the adjustable positioning fixture (31) is pneumatically controlled. The pneumatically controlled moving block is slidably installed on the guide rail on the top surface of the bottom plate of the welding device body (1). The displacement adjustment component (32) consists of a servo motor (3201) and a double threaded rod (3202). The servo motor (3201) is electrically connected to the welding device body (1), and the double threaded rod (3202) is connected to the right threaded hole of the adjustable positioning fixture (31) through a thread. The pressure sensor (33) is embedded inside the adjustable positioning fixture (31). The moving part (4) includes a distance sensor (41), an electric moving part (42), and a track assembly (43). The distance sensor (41) is a laser distance sensor, which is installed at the end of the welding torch connector (21). The electric moving part (42) is slidably connected to the track assembly (43). The moving part (4) is electrically connected to the control end of the welding device body (1) and receives control commands to adjust the moving trajectory and speed.

2. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The welding process database pre-stores welding parameters for two commonly used sanitation box plates: carbon steel and stainless steel. The welding current for carbon steel plates is 80-200A, the voltage is 15-25V, and the wire feed speed is 3-8m / min. The welding current for stainless steel plates is 60-180A, the voltage is 12-22V, and the wire feed speed is 2-6m / min. The database also supports custom parameter input and updates. The PLC control system adopts a three-level main power topology with an inverter frequency of less than 110KHz.

3. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The arc ignition optimization module (8) controls the welding torch to perform an adaptive arc ignition wire retraction action based on the plate thickness data obtained by the plate parameter identification module (7), and optimizes the current and voltage parameters during the arc ignition stage.

4. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The welding robotic arm (2) is a six-axis robotic arm. The welding robotic arm (2) is electrically connected to the control end of the welding device body (1) via a cable, receives control commands and executes welding actions. The end of the welding torch connector (21) is provided with a buckle plate. A pull plate (2101) is slidably engaged inside the buckle plate. A buckle plate (2102) is engaged below the pull plate (2101) and inside the buckle plate. The bottom of the pull plate (2101) is connected to the bottom surface of the sliding groove inside the buckle plate via a built-in spring telescopic rod. The two sides of the pull plate (2101) are connected to the connecting rod (21011) via a shaft. The end of the connecting rod (21011) is connected to the buckle cone (21012) via a shaft. The buckle cone (21012) is engaged at the end of the welding robotic arm (2).

5. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The adjustable positioning clamp (31) is adapted to the splicing and positioning of the side plate and bottom plate of the sanitation box, and the side plate and the side plate. A bidirectional telescopic connecting rod (3101) is connected between the two adjustable positioning clamps (31). Protruding rectangular plates are provided on the left and right sides of the adjustable positioning clamp (31). A movable plate is fixedly connected to the bottom of the two adjustable positioning clamps (31) corresponding to the front and rear positions. A locking strip is fixedly provided on the top surface of the movable plate. The locking strip is installed above the rectangular plates on both sides of the adjustable positioning clamp (31). A rubber anti-scratch pad is provided on the inner side of the adjustable positioning clamp (31).

6. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The parameter adaptive adjustment module (5) is electrically connected to the welding device body (1), welding robotic arm (2) and moving part (4), and is used to obtain the plate data transmitted by the plate parameter identification module (7) and the distance data detected by the distance sensor (41).

7. The automatic welding device for welding sanitation boxes as described in claim 3, characterized in that: The plate parameter identification module (7) includes a visual recognition camera (71) and a thickness detection sensor (72). Both the visual recognition camera (71) and the thickness detection sensor (72) are installed on the side of the welding torch connector (21). Both transmit the identification data to the PLC control system of the main body of the welding device (1). The control system combines the welding process database to automatically match the optimal welding parameters.

8. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The main body (1) of the welding device is equipped with a 10-inch touch operation panel and an Ethernet remote communication interface, and supports the storage and export of welding data. A hanging rail (11) is fixedly welded to the bottom surface of the top plate of the main body (1). An electric drive slider is slidably connected to the hanging rail (11). A telescopic rod (12) is installed at the bottom of the electric drive slider. The telescopic rod (12) is electrically connected to the PLC control system. A stop plate (13) is installed at the end of the telescopic rod (12). A sensor is embedded in the stop plate (13). A right-angle connecting plate (14) is installed on the bottom plate of the main body (1) and on the electric drive moving part (42). An inner sliding groove plate (1401) is fixedly connected to the upright plate of the right-angle connecting plate (14). A connecting block is slidably connected inside the inner sliding groove plate (1401). A telescopic rod is installed on the bottom and inner side of the connecting block. The end of the telescopic rod on the inner side is connected to the welding monitoring module (6) by a hexagonal screw. The telescopic rod is electrically connected to the PLC control system.

9. The automatic welding device for welding sanitation boxes as described in claim 1, characterized in that: The welding monitoring module (6) includes a weld formation monitoring camera (61) and a temperature sensor (62). The weld formation monitoring camera (61) is used to capture the weld formation status in real time. The temperature sensor (62) is an infrared temperature sensor used to detect the temperature of the welding area. Both the weld formation monitoring camera (61) and the temperature sensor (62) transmit the monitoring data to the PLC control system of the main body of the welding device (1).

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