Automatic welding equipment for diesel generating set

Abstract

An automatic welding device for diesel generator sets is disclosed. This relates to the field of welding equipment. It includes: a feeding mechanism comprising a base and several rollers, wherein the workpiece to be welded can be fixed on the base or slide on top of the rollers; a welding mechanism comprising a moving component and a welding component, wherein the moving component includes a pair of fixed beams, a movable crossbeam, and a movable vertical beam; the welding component includes an assembly housing and welding torches, wherein a pair of welding torches are symmetrically arranged on both sides of the assembly housing, one end of each welding torch is movably connected to the assembly housing, and the other end of each welding torch extends outward from the assembly housing and can rotate around one end of the welding torch. In this application, the feeding mechanism, in conjunction with the moving component of the welding mechanism, drives the welding component to move, automatically adjusting the welding position, reducing manual intervention in workpiece loading / unloading, positioning, and welding path adjustment, and improving the parameter stability and production efficiency of the welding process.

Description

Technical Field

[0001] This application relates to the field of welding equipment, specifically to an automatic welding device for diesel generator sets. Background Technology

[0002] Currently, there are two main modes of welding operations for diesel generator sets in the industry: one is to use simple semi-automatic or fixed welding equipment, and the other is to introduce high-precision fully automatic welding robot workstations.

[0003] However, both models have significant limitations. While the initial investment cost of simple welding equipment is lower, its automation level is limited. It often requires a lot of manual intervention for workpiece loading and unloading, positioning, and welding path adjustment, resulting in poor parameter stability during the welding process. The weld quality is highly dependent on the skill level and proficiency of the operators, making it prone to welding defects and resulting in low production efficiency. This makes it difficult to meet the requirements of consistency and high efficiency for modern industrialized mass production.

[0004] On the other hand, while fully automated welding robots can achieve high-precision, high-efficiency unmanned welding and significantly improve product quality, their equipment procurement costs are high, typically requiring an investment of hundreds of thousands or even millions of yuan. Furthermore, fully automated robot systems have complex structures, demanding extremely high levels of expertise from operators and maintenance personnel, and the subsequent costs of programming, debugging, troubleshooting, and maintenance are also considerable. For most small and medium-sized enterprises, this high-cost automation solution has an excessively long payback period, placing a heavy economic burden on them and hindering widespread adoption.

[0005] Therefore, how to develop a compromise solution that can overcome the shortcomings of traditional simple equipment with low automation and reliance on manual labor, while ensuring welding quality and efficiency, and avoid the high cost and high maintenance threshold of fully automatic welding robots, has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] In order to overcome the contradiction between the low level of automation of traditional simple equipment and the high cost and high maintenance threshold of fully automatic welding robots in the prior art, this application provides an automatic welding equipment for diesel generator sets.

[0007] This application adopts the following technical solution: an automatic welding equipment for diesel generator sets, comprising: a feeding mechanism, the feeding mechanism including a base and several rollers, wherein the workpiece to be welded can be fixed on the base or slide on the top of the several rollers; a welding mechanism, the welding mechanism including a moving component and a welding component, the moving component including a pair of fixed beams, a movable crossbeam and a movable vertical beam, the two ends of the movable crossbeam being respectively and correspondingly mounted on the top of the pair of fixed beams, the movable vertical beam being mounted on the outside of the movable crossbeam, the movable crossbeam being reciprocating along the length direction of the fixed beams, and the movable vertical beam being reciprocating along the length and height directions of the movable crossbeam; the welding component including an assembly shell and a welding torch, the pair of welding torches being symmetrically arranged on both sides of the assembly shell, one end of the welding torch being movably connected to the assembly shell, and the other end of the welding torch extending outside the assembly shell and being rotatable around one end of the welding torch.

[0008] By adopting the above technical solutions, the feeding mechanism can realize fixed or sliding feeding of workpieces, reducing manual intervention; the moving component of the welding mechanism enables the movable crossbeam and movable vertical beam to move back and forth in different directions, and the welding position can be flexibly adjusted; the pair of welding guns of the welding component can rotate around one end, which can adapt to different welding needs and improve the flexibility and efficiency of welding.

[0009] Preferably, the base includes a pair of support seats and an elongated groove. Each of the top sides of the pair of support seats is provided with a notch, and the pair of notches are spaced apart and arranged opposite to each other. The elongated groove is adapted to be placed in the pair of notches, and a plurality of rollers are disposed in the elongated groove and spaced apart along the length of the elongated groove.

[0010] By adopting the above technical solution, the base of the feeding mechanism consists of a pair of support seats and a long groove. The long groove is adapted to be placed in the notch of the support seat, and the roller is set in the long groove, which makes it easy for the workpiece to be welded to slide on the top of the roller or be fixed on the base. This provides a stable support and a moving foundation for the feeding of the workpiece, which helps to improve the stability and convenience of feeding, and thus helps to improve the efficiency of welding operations.

[0011] Preferably, a plurality of synchronously retractable hydraulic cylinders are provided below the elongated groove, and the plurality of hydraulic cylinders are used to drive the elongated groove to move in the vertical direction; when the piston rod of the hydraulic cylinder is in the retracted state, the top height of the plurality of rollers is lower than the top height of the support base; when the piston rod of the hydraulic cylinder is in the extended state and locked, the top height of the plurality of rollers is higher than the top height of the support base; the width of the workpiece is greater than the distance between a pair of support bases.

[0012] By adopting the above technical solution, a long trough body is driven to move vertically using a synchronously retractable hydraulic cylinder. When the piston rod retracts, the top height of the idler roller is lower than the top height of the support base, which can stably fix the workpiece on the support base. When the piston rod extends and locks, the top height of the idler roller is higher than the top height of the support base, which allows the workpiece to slide on the top of the idler roller, facilitating the loading and unloading of the workpiece. This overcomes the shortcomings of traditional simple equipment, such as low automation and reliance on manual labor, and improves the automation level and ease of operation of the equipment. At the same time, it avoids the use of high-cost fully automatic welding robots, thus reducing costs.

[0013] Preferably, the assembly housing is inverted U-shaped, and a drive shaft and a driven shaft are provided inside the assembly housing. A drive gear is provided on the drive shaft, and a driven gear is provided on the driven shaft. The drive gear and the driven gear mesh. An electric motor is provided on the outside of the assembly housing, and the electric motor is used to drive the drive shaft to rotate. Both the drive shaft and the driven shaft are provided with swing arms. The welding torch is located at the end of the swing arm. One welding torch rotates around the axis of the drive shaft, and the other welding torch rotates around the axis of the driven shaft.

[0014] By adopting the above technical solution, the feeding mechanism can realize fixed or sliding feeding of workpieces. The moving component of the welding mechanism can make the movable crossbeam and movable vertical beam move in multiple directions. The assembly shell is U-shaped and is equipped with a drive shaft, a driven shaft, and meshing drive and driven gears inside. The drive shaft is driven by an electric motor to rotate, which drives the welding gun at the end of the swing arm on the drive shaft and the driven shaft to rotate around the axis of the drive shaft and the driven shaft, respectively. The position and angle of the welding gun can be flexibly adjusted to improve the flexibility and adaptability of welding.

[0015] Preferably, the drive shaft and the driven shaft are both connected to the inner wall of the assembly housing via bearings, and the end of the swing arm located inside the assembly housing is arc-shaped; the drive gear and the driven gear are both half gears, and when the drive gear and the driven gear are in meshing state, the angle between the welding torch and the horizontal plane does not exceed 90°.

[0016] By adopting the above technical solutions, the drive shaft and driven shaft are connected to the inner wall of the assembly housing through bearings, which can reduce the frictional resistance during rotation and make the drive shaft and driven shaft rotate more smoothly; the arc-shaped end of the swing arm can avoid interference when moving inside the assembly housing; the drive gear and driven gear are half gears and the angle between the welding torch and the horizontal plane does not exceed 90° when meshing, which can accurately control the rotation angle and range of the welding torch and improve the flexibility and accuracy of welding.

[0017] Preferably, the top of the assembly housing is provided with a pair of one-way cylinders, and the push rods of the one-way cylinders extend to the inner side of the assembly housing; the top of each pair of swing arms is provided with a first rotating seat, and the push rods of the pair of one-way cylinders and the pair of first rotating seats are respectively and corresponding to each other.

[0018] By adopting the above technical solution, a pair of one-way cylinders and their push rods are set on the top of the assembly shell and are correspondingly set with the first rotating seat on the top of the swing arm. This can lock the swing arm in the vertical direction, ensuring the stability of the swing arm in the vertical position, improving the accuracy of the welding torch position during the welding process, and thus improving the welding quality.

[0019] Preferably, the one-way cylinder is used to lock a pair of the swing arms in the vertical direction, and the push rod of the one-way cylinder is movably connected to the first rotating seat and can move around the circumference of the first rotating seat.

[0020] By adopting the above technical solution, the push rod of the one-way cylinder can be movably connected to the first rotating seat and can move around it in the circumference, which can effectively fix the position of the swing arm in the vertical direction, while ensuring that the horizontal extension and retraction of the one-way cylinder causes the swing arm to rotate.

[0021] Preferably, the inner side of the assembly shell is also provided with a bidirectional cylinder, and a second rotating seat is provided at the bottom of each pair of swing arms. The two push rods of the bidirectional cylinder are respectively and corresponding to the pair of second rotating seats.

[0022] By adopting the above technical solution, the bidirectional cylinder can lock a pair of swing arms in the horizontal direction, and the push rod of the bidirectional cylinder can be movably connected to the second rotating seat, which further enhances the stability and adjustability of the swing arms and improves the accuracy and flexibility of the welding process.

[0023] Preferably, the bidirectional cylinder is used to lock a pair of the swing arms in the horizontal direction, and the push rod of the bidirectional cylinder is movably connected to the second rotating seat and can move around the circumference of the second rotating seat.

[0024] By adopting the above technical solution, the bidirectional cylinder locks the swing arm in the horizontal direction, and the push rod is movably connected to the second rotating seat and can move in the circumferential direction. This can stabilize the welding torch in the horizontal direction while ensuring a certain degree of freedom of movement, thereby improving the adaptability and stability of welding.

[0025] In summary, this application includes the following beneficial technical effects: 1. The base and rollers of the feeding mechanism can fix or slide the workpiece to be welded. Combined with the moving components of the welding mechanism, they drive the welding components to move, automatically adjusting the welding position. This reduces manual intervention in workpiece loading / unloading, positioning, and welding path adjustment, overcoming the shortcomings of traditional simple equipment with low automation and reliance on manual labor, and improving the parameter stability and production efficiency of the welding process. 2. The components of the feeding mechanism and welding mechanism cooperate with each other. The movable crossbeam and movable vertical beam can move flexibly, and the welding torch can rotate, enabling precise control of the welding position and angle, ensuring welding quality, and meeting the requirements of consistency and high efficiency in modern industrial mass production. Attached Figure Description

[0026] Figure 1 This is a schematic perspective view of this application; Figure 2 It is a schematic 3D diagram of the welding mechanism; Figure 3 This is a reference diagram showing the explosion state of the welding mechanism; Figure 4 This is a reference diagram showing the assembly status of the swing arm and welding torch; Figure 5 This is a reference diagram showing the explosion state of the feeding mechanism; In the diagram: 1. Feeding mechanism; 11. Base; 111. Support seat; 112. Long trough; 113. Notch; 12. Idler roller; 13. Hydraulic cylinder; 2. Welding mechanism; 21. Fixed beam; 22. Movable crossbeam; 23. Movable vertical beam; 24. Assembly shell; 241. Drive shaft; 242. Driven shaft; 243. Drive gear; 244. Driven gear; 245. Electric motor; 246. Swing arm; 247. First rotating seat; 248. Second rotating seat; 25. Welding torch; 26. One-way cylinder; 27. Two-way cylinder. Detailed Implementation

[0027] The present application will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0028] like Figure 1-5 As shown in the embodiment of this application, an automatic welding equipment for diesel generator sets includes a feeding mechanism 1 and a welding mechanism 2. The feeding mechanism 1 is used to transport the workpiece to be welded, and the welding mechanism 2 is used to weld the workpiece. The two work together to improve the automation and efficiency of welding, and reduce the purchase, maintenance and use costs of production equipment.

[0029] The feeding mechanism 1 includes a base 11 and several idler rollers 12. The base 11 includes a pair of support seats 111 and a long groove 112. Each of the support seats 111 has a notch 113 on one side of its top, and the notches 113 are spaced apart and opposite to each other. The long groove 112 is fitted into the notches 113, and the several idler rollers 12 are disposed within the long groove 112 and spaced apart along its length. The support seats 111 are typically made of metal, providing high strength and stability. The long groove 112 is generally rectangular, and the idler rollers 12 can be cylindrical, facilitating workpiece sliding. The workpiece to be welded can be fixed to the base 11 or slide on top of the idler rollers 12. Several synchronously extendable hydraulic cylinders 13 are located below the long groove 112, driving the long groove 112 to move vertically. When the piston rod of the hydraulic cylinder 13 is in the retracted state, the top height of the rollers 12 is lower than the top height of the support base 111, allowing the workpiece to be placed on the support base 111. When the piston rod of the hydraulic cylinder 13 is in the extended and locked state, the top height of the rollers 12 is higher than the top height of the support base 111, allowing the workpiece to slide on the rollers 12 for easy feeding. The width of the workpiece is greater than the distance between a pair of support bases 111, ensuring that the workpiece is stably placed on the feeding mechanism 1.

[0030] The working principle of the feeding mechanism 1 is as follows: the support base 111 provides support for the elongated trough 112 and the idler roller 12. The elongated trough 112 accommodates the idler roller 12 and moves up and down under the drive of the hydraulic cylinder 13. The idler roller 12 is used to support and transport the workpiece. This combination makes the feeding process more flexible, allowing the workpiece to be fixed on the base 11 or to slide on the idler roller 12, meeting different welding requirements. The combined effect is improved feeding efficiency and flexibility, enabling it to adapt to workpieces of different sizes and shapes.

[0031] The welding mechanism 2 includes a moving component and a welding component. The moving component includes a pair of fixed beams 21, a movable crossbeam 22, and a movable vertical beam 23. The two ends of the movable crossbeam 22 are respectively and correspondingly mounted on top of the pair of fixed beams 21. The movable vertical beam 23 is mounted on the outside of the movable crossbeam 22. The movable crossbeam 22 can reciprocate along the length of the fixed beams 21, and the movable vertical beam 23 can reciprocate along the length and height of the movable crossbeam 22. The movement of the movable crossbeam 22 and the movable vertical beam 23 can be achieved by a motor and a transmission device, such as a rack and pinion drive or a lead screw and nut drive. The welding component includes an assembly housing 24 and welding torches 25. A pair of welding torches 25 are symmetrically arranged on both sides of the assembly housing 24. One end of each welding torch 25 is movably connected to the assembly housing 24, and the other end extends to the outside of the assembly housing 24 and can rotate around one end of the welding torch 25. The assembly housing 24 is inverted U-shaped. Inside the assembly housing 24 are a drive shaft 241 and a driven shaft 242. A drive gear 243 is mounted on the drive shaft 241, and a driven gear 244 is mounted on the driven shaft 242. The drive gear 243 and driven gear 244 mesh. A motor 245 is located on the outside of the assembly housing 24, driving the drive shaft 241 to rotate. Both the drive shaft 241 and driven shaft 242 are connected to the inner wall of the assembly housing 24 via bearings, which reduces friction during rotation and improves rotational flexibility. The end of the swing arm 246 located inside the assembly housing 24 is arc-shaped; this design prevents interference between the swing arm 246 and the assembly housing 24 during rotation. Both the drive gear 243 and driven gear 244 are half-gears. When the drive gear 243 and driven gear 244 are meshed, the angle between the welding torch 25 and the horizontal plane does not exceed 90°, ensuring that the welding torch 25 performs welding within a suitable angle range.

[0032] The top of the assembly housing 24 is provided with a pair of one-way cylinders 26, the push rods of which extend to the inner side of the assembly housing 24. Each of the tops of a pair of swing arms 246 is provided with a first rotating seat 247. The push rods of the one-way cylinders 26 and the first rotating seats 247 are respectively and correspondingly arranged. The one-way cylinders 26 are used to lock the pair of swing arms 246 vertically. The push rods of the one-way cylinders 26 are movably connected to the first rotating seats 247 and can move around the circumference of the first rotating seats 247. The inner side of the assembly housing 24 is also provided with a two-way cylinder 27. Each of the bottoms of the pair of swing arms 246 is provided with a second rotating seat 248. The two push rods of the two-way cylinder 27 and the second rotating seats 248 are respectively and correspondingly arranged. The two-way cylinders 27 are used to lock the pair of swing arms 246 horizontally. The push rods of the two-way cylinders 27 are movably connected to the second rotating seats 248 and can move around the circumference of the second rotating seats 248. Since circumferential movement can occur between the one-way cylinder 26 and the first rotating seat 247, and between the two-way cylinder 27 and the second rotating seat 248, it is ensured that the linear movement of the one-way cylinder 26 and the two-way cylinder 27 and the rotation of the swing arm 246 will not interfere with each other, thereby ensuring that the locking effect of the one-way cylinder 26 and the two-way cylinder 27 on the swing arm 246 is reliable.

[0033] The working principle of welding mechanism 2 is as follows: the moving component provides the basis for the movement of the welding component, enabling the welding torch 25 to reach different welding positions. The drive shaft 241 and driven shaft 242 in the welding component drive the swing arm 246 to rotate through gear transmission, thereby realizing the rotation of the welding torch 25. The one-way cylinder 26 and the two-way cylinder 27 are used to lock the swing arm 246 to ensure the stability of the welding torch 25 during the welding process.

[0034] The implementation principle of this embodiment is as follows: The automatic welding equipment for diesel generator sets in this embodiment achieves automation of diesel generator set welding through the coordinated work of the feeding mechanism 1 and the welding mechanism 2. The design of the feeding mechanism 1 makes the feeding of workpieces more flexible and efficient, and can adapt to workpieces of different sizes and shapes. The design of the welding mechanism 2 allows the welding torch 25 to flexibly adjust its position and angle, improving the welding accuracy and quality. Compared with traditional semi-automatic or fixed welding equipment, this equipment reduces manual intervention and improves the stability of parameters and weld quality during the welding process. Compared with fully automatic welding robots, this equipment has a relatively simple structure, lower cost, and lower maintenance threshold, making it suitable for use by a wide range of small and medium-sized enterprises. While ensuring welding quality and efficiency, this equipment overcomes the shortcomings of traditional simple equipment, such as low automation and reliance on manual labor, and avoids the problems of high cost and high maintenance threshold of fully automatic welding robots.

[0035] The above embodiments are merely preferred embodiments of this application and should not be construed as limiting the scope of protection of this application. Any non-substantial changes and substitutions made by those skilled in the art based on this application shall fall within the scope of protection claimed by this application.

Claims

1. An automatic welding equipment for diesel generator sets, characterized in that, include: The feeding mechanism (1) includes a base (11) and several rollers (12). The workpiece to be welded can be fixed on the base (11) or slide on the top of the rollers (12). Welding mechanism (2), the welding mechanism (2) includes a moving component and a welding component. The moving component includes a pair of fixed beams (21), a movable crossbeam (22) and a movable vertical beam (23). The two ends of the movable crossbeam (22) are respectively and correspondingly mounted on the top of the pair of fixed beams (21). The movable vertical beam (23) is mounted on the outside of the movable crossbeam (22). The movable crossbeam (22) can reciprocate along the length direction of the fixed beams (21). The movable vertical beam (23) can reciprocate along the length and height directions of the movable crossbeam (22). The welding assembly includes an assembly shell (24) and a welding torch (25). A pair of welding torches (25) are symmetrically arranged on both sides of the assembly shell (24). One end of the welding torch (25) is movably connected to the assembly shell (24), and the other end of the welding torch (25) extends out of the assembly shell (24) and can rotate around one end of the welding torch (25).

2. The automatic welding equipment for diesel generator sets according to claim 1, characterized in that, The base (11) includes a pair of support seats (111) and a long groove (112). Each of the pair of support seats (111) has a notch (113) on one side of its top. The pair of notches (113) are spaced apart and arranged opposite to each other. The long groove (112) is adapted to be placed in a pair of notches (113), and a plurality of rollers (12) are disposed in the long groove (112) and spaced apart along the length of the long groove (112).

3. The automatic welding equipment for diesel generator sets according to claim 2, characterized in that, The long groove (112) is provided with several hydraulic cylinders (13) that can be synchronously extended and retracted. The hydraulic cylinders (13) are used to drive the long groove (112) to move in the vertical direction. When the piston rod of the hydraulic cylinder (13) is in the retracted state, the top height of some of the rollers (12) is lower than the top height of the support (111); When the piston rod of the hydraulic cylinder (13) is in the extended and locked state, the top height of some of the rollers (12) is higher than the top height of the support (111); The width of the workpiece is greater than the distance between the pair of supports (111).

4. The automatic welding equipment for diesel generator sets according to claim 2, characterized in that, The assembly housing (24) is U-shaped. Inside the assembly housing (24) are a drive shaft (241) and a driven shaft (242). The drive shaft (241) is provided with a drive gear (243), and the driven shaft (242) is provided with a driven gear (244). The drive gear (243) and the driven gear (244) mesh. An electric motor (245) is provided on the outside of the assembly housing (24). The electric motor (245) is used to drive the drive shaft (241) to rotate. Both the drive shaft (241) and the driven shaft (242) are provided with a swing arm (246), and the welding torch (25) is disposed at the end of the swing arm (246). One welding torch (25) rotates around the axis of the drive shaft (241), and the other welding torch (25) rotates around the axis of the driven shaft (242).

5. The automatic welding equipment for diesel generator sets according to claim 4, characterized in that, The drive shaft (241) and the driven shaft (242) are both connected to the inner wall of the assembly housing (24) by bearings, and the end of the swing arm (246) located inside the assembly housing (24) is arc-shaped. Both the driving gear (243) and the driven gear (244) are half gears. When the driving gear (243) and the driven gear (244) are in meshing, the angle between the welding torch (25) and the horizontal plane does not exceed 90°.

6. The automatic welding equipment for diesel generator sets according to claim 5, characterized in that, The top of the assembly housing (24) is provided with a pair of one-way cylinders (26), and the push rods of the one-way cylinders (26) extend to the inside of the assembly housing (24). Each of the pair of swing arms (246) is provided with a first rotating seat (247) at its top, and the push rods of the pair of one-way cylinders (26) are respectively and one-to-one corresponding to the pair of first rotating seats (247).

7. The automatic welding equipment for diesel generator sets according to claim 6, characterized in that, The one-way cylinder (26) is used to lock a pair of the swing arms (246) in the vertical direction. The push rod of the one-way cylinder (26) is movably connected to the first rotating seat (247) and can move around the circumference of the first rotating seat (247).

8. The automatic welding equipment for diesel generator sets according to claim 5, characterized in that, The inner side of the assembly shell (24) is also provided with a two-way cylinder (27), and a second rotating seat (248) is provided at the bottom of each pair of swing arms (246). The two push rods of the two-way cylinder (27) are respectively and one-to-one corresponding to the pair of second rotating seats (248).

9. An automatic welding equipment for diesel generator sets according to claim 8, characterized in that, The bidirectional cylinder (27) is used to lock a pair of the swing arms (246) in the horizontal direction. The push rod of the bidirectional cylinder (27) is movably connected to the second rotating seat (248) and can move around the second rotating seat (248) in the circumference.

Images