A laser wire filling based automobile air conditioner condenser robot welding process equipment

Abstract

The application discloses a kind of based on laser wire filling welding's automobile air conditioner condenser robot welding process equipment, it is related to automobile air conditioner condenser welding technical field, welding mechanism includes: double-station transfer machine, welding assembly and welding tooling, double-station transfer machine is set to six-axis welding robot opposite side has double-station transfer machine, rotation servo is set on the double-station transfer machine, cam divider, are connected with control system by circuit, by being provided with double-station transfer machine, guaranteeing that product can be synchronously welded while feeding and discharging, improves overall operation efficiency, improves production capacity, robot automatic laser wire filling welding equipment, can completely isolate laser radiation and welding fume, avoid burning eyes and skin, solve the professional health risk when artificial welding.At the same time, robot replaces artificial to complete close-range welding operation, avoids direct damage to human body of high temperature, strong light, reduces the probability of equipment collision, misoperation and other safety accidents.

Description

Technical Field

[0001] This invention relates to the field of automotive air conditioning condenser welding technology, specifically to a robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding. Background Technology

[0002] Laser filler wire welding is a composite technology combining laser deep penetration welding and filler wire processes. It uses a laser beam to melt the base material and filler wire to form a metallurgically bonded joint. The core technical objective is to overcome the limitations of traditional laser welding, such as sensitivity to assembly gaps and inability to repair material defects, by supplementing material with filler wire, while retaining the high precision and low deformation advantages of laser welding.

[0003] According to the patent titled "An Automotive Parts Laser Welding Equipment Component" (Patent Publication No.: CN110695529A, Patent Publication Date: 2020-01-17), it includes a laser welding machine body and a movable support mechanism distributed at the bottom of the laser welding machine body. The movable support mechanism includes a support base and four clamping and fixing mechanisms evenly distributed around the edge of the support base. Movable buffer mechanisms are evenly distributed around the bottom of the support base. Through a scientifically designed structure, the laser welding machine can be moved freely and effectively buffered during movement to avoid damage caused by vibration. Simultaneously, it can be stably fixed and adjusted when no movement is needed. The structure is simple, easy to use, and suitable for supporting and fixing laser welding machines of various sizes, possessing good practical and promotional value.

[0004] Based on the aforementioned existing technologies, the current robotic welding equipment for automotive air conditioning condensers based on laser filler wire welding still has the following problems: traditional welding equipment is mostly single-station, and welding needs to be stopped for loading and unloading during the welding process, resulting in significant waiting time and low welding efficiency. Therefore, this invention provides a robotic welding equipment for automotive air conditioning condensers based on laser filler wire welding. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding. This solves the following problems of existing robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding: traditional welding equipment is mostly single-station, and welding needs to be stopped for loading and unloading during the welding process, resulting in significant waiting time and low welding efficiency.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding, comprising a dual six-axis welding robot, a control cabinet, a safety fence, loading and unloading stations, a welding station, and a welding mechanism, wherein the welding mechanism includes: A dual-station positioner is set on the opposite side of the six-axis welding robot. The dual-station positioner is equipped with a rotary servo and a cam divider, both of which are connected to the control system via circuits. The cam divider achieves planar rotation, enabling simultaneous loading, unloading, and welding. The servo reducer achieves axial rotation, and the rotary bearings enable the tooling tables on both sides of the cam divider to rotate 180 degrees. Welding components are mounted on the execution end of a six-axis welding robot. Welding fixtures are installed on a dual-station positioner.

[0007] Preferably, the dual-station positioner further includes a positioner frame, the cam divider is fixed to the ground by a mounting base, the servo reducer and the rotary bearing are mounted on the positioner frame, the positioner frame is fixed to the cam divider by a connecting plate, and the tooling table is fixed to the servo reducer by a rotating connecting plate, so as to achieve 180-degree rotation of the table.

[0008] Preferably, the tooling table surface has pre-drilled positioning pin holes and threaded holes to enable quick change of welding tooling.

[0009] Preferably, the positioning pin holes and threaded holes on the tooling table are symmetrically distributed and correspond to the positioning pins and mounting holes at the bottom of the welding tooling.

[0010] Preferably, the welding assembly includes a welding head, a laser, a wire feeder, a water cooler, a mounting plate, and a wire feeding gun, with the wire feeding gun installed below the welding head. The welding head, the wire feeder, and the mounting plate are connected. The laser and the water cooler are both installed at the welding station. The wire feeder pushes the welding wire to achieve speed-adjustable wire feeding. The mounting plate is connected to the flange plate of the six-axis welding robot.

[0011] Preferably, the mounting plate is provided with an assembly interface for mounting the welding head and the wire feeder, and the position of the assembly interface matches the mounting surface of the flange plate of the six-axis welding robot.

[0012] Preferably, the welding fixture includes a dead stop limit block, a quick clamp, a fixture base plate, a contour support structure, a manual valve, a cylinder pushing structure, and a lower right bracket. The product body is fixed by the dead stop limit block and the quick clamp. The dead stop limit blocks are respectively installed on the fixture base plate. The fixture base plate is connected and fixed into a whole by fixture connecting strips. The front and rear positions of the lower right bracket are positioned by the contour support structure.

[0013] Preferably, the manual valve controls the cylinder pushing structure to ensure that the welding bracket is tightly fitted to the product body, and a liquid storage tank bracket is provided on the tooling base plate.

[0014] This invention provides a robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding. Compared with existing technologies, it has the following advantages: 1. This robotic welding equipment for automotive air conditioning condensers, based on laser wire filler welding, features a dual-station positioner that ensures simultaneous welding of products during loading and unloading, improving overall operational efficiency and increasing production capacity. The robotic automatic laser wire filler welding equipment completely isolates laser radiation and welding fumes, preventing eye and skin burns and eliminating occupational health risks associated with manual welding. Furthermore, the robot replaces manual labor in close-range welding operations, avoiding direct harm from high temperatures and strong light, and reducing the probability of accidents such as equipment collisions and misoperations.

[0015] 2. This robotic welding equipment for automotive air conditioning condensers, based on laser-assisted wire feeding welding, employs a dual six-axis welding robot integrated welding assembly for fully automated operation. Laser radiation and welding fumes are completely isolated by a safety fence. The laser and wire feeder within the welding assembly are precisely controlled by a control cabinet, achieving intelligent matching of laser power, wire feeding speed, and robot motion trajectory to ensure weld quality. This automated working principle not only avoids the occupational health risks and safety accidents associated with manual welding but also ensures the stability of the welding process and the consistency of the weld through parametric control.

[0016] 3. This robotic welding equipment for automotive air conditioning condensers based on laser filler wire welding achieves high-precision positioning and rapid changeover of the product body through dead-stop limiting blocks, quick clamps, contour support structures, and cylinder pushing structures set in the welding fixture, in conjunction with the positioning pin holes and threaded holes reserved on the fixture table. Its working principle is as follows: the dead-stop limiting blocks and contour support structures precisely limit the position of the product body and components such as the lower right bracket, providing stable and reliable clamping force for the quick clamps and cylinder pushing structures, ensuring no workpiece displacement during welding; simultaneously, the positioning pin holes on the fixture table cooperate with the positioning pins and mounting holes on the bottom of the welding fixture to achieve rapid positioning and installation of the welding fixture, significantly shortening changeover time and improving the equipment's adaptability to different product models and production flexibility. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the overall appearance of the present invention; Figure 2 This is a three-dimensional structural diagram of the welding assembly of the present invention; Figure 3 This is a three-dimensional structural diagram of the welding fixture of the present invention; Figure 4 This is a three-dimensional structural diagram of the dual-station positioner of the present invention; Figure 5 This is a three-dimensional structural diagram of the welding process for front welding according to the present invention; Figure 6 This is a three-dimensional structural diagram of the welding process for reverse welding according to the present invention.

[0018] In the diagram: 1. Dual six-axis welding robot; 2. Dual-station positioner; 21. Cam divider; 22. Servo reducer; 23. Slewing bearing; 24. Mounting base; 25. Tooling table; 26. Positioner frame; 28. Rotary connecting plate; 3. Welding assembly; 31. Welding head; 32. Laser; 33. Wire feeder; 34. Water chiller; 35. Mounting plate; 36. Flange plate of the six-axis welding robot; 37. Wire feeder; 4. Welding fixture; 41. Dead stop limit block; 42. Quick clamp; 43. Fixture base plate; 44. Fixture connecting strip; 45. Contouring support structure; 46. Manual valve; 47. Cylinder pushing structure; 48. Lower right bracket; 49. Liquid storage tank bracket; 5. Control cabinet; 6. Safety fence; 7. Loading and unloading station; 8. Welding station. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some 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.

[0020] Please see Figures 1-6 The present invention provides a technical solution: A robotic welding process equipment for automotive air conditioning condensers based on laser wire filler welding includes a dual six-axis welding robot 1, a control cabinet 5, a safety fence 6, a loading and unloading station 7, a welding station 8, and a welding mechanism. The welding mechanism includes: A dual-station positioner 2 is set on the opposite side of the six-axis welding robot 1. The dual-station positioner 2 is equipped with a rotary servo 22 and a cam divider 21, both of which are connected to the control system via circuits. The cam divider 21 realizes planar rotation, enabling simultaneous loading, unloading and welding. The servo reducer 22 realizes axial rotation. The rotary bearing 23 enables the tooling tables 25 set on both sides of the cam divider 21 to rotate 180 degrees. Welding component 3 is installed at the execution end of the six-axis welding robot 1; Welding fixture 4 is installed on the dual-station positioner 2.

[0021] In this embodiment, the dual-station positioner 2 also includes a positioner frame 26. The cam divider 21 is fixed to the ground by the mounting base 24. The servo reducer 22 and the rotary bearing 23 are mounted on the positioner frame 26. The positioner frame 26 is fixed to the cam divider 21 by the connecting plate. The tooling table 25 is fixed to the servo reducer 22 by the rotating connecting plate 28, so as to realize the 180-degree rotation of the table.

[0022] In this embodiment, the tooling table 25 has reserved positioning pin holes and threaded holes to enable quick change of welding tooling 4.

[0023] In this embodiment, the positioning pin holes and threaded holes provided on the tooling table 25 are symmetrically distributed and correspond to the positioning pins and mounting holes at the bottom of the welding tooling 4.

[0024] In this embodiment, the welding assembly 3 includes a welding head 31, a laser 32, a wire feeder 33, a water chiller 34, a mounting plate 35, and a wire feed gun 37. The wire feed gun 37 is installed below the welding head 31. The welding head 31, the wire feeder 33, and the mounting plate 35 are connected. The laser 32 and the water chiller 34 are both installed on the welding station 8. The wire feeder 33 pushes the welding wire to achieve speed-adjustable wire feeding. The mounting plate 35 is connected to the flange plate 36 of the six-axis welding robot.

[0025] Laser 32 is the core of the welding assembly. Its function is to convert electrical energy or other energy into a high-energy-density laser beam to provide a heat source for welding. Specific functions include: generating a focused laser beam, adjusting laser parameters to adapt to the process, and ensuring stable beam quality. Welding head 31 is a key component connecting the laser optical path to the workpiece. Its core function is to accurately transmit and focus the laser beam and assist in completing the welding process. Specific functions include: laser beam transmission and focusing, and integrating auxiliary welding functions, such as wire feeder 37. The core function of chiller 34 is to achieve precise temperature control through circulating cooling water, ensuring stable operation and service life of the equipment. Cooling laser 32 is the core component, and cooling welding head 31 is the optical assembly.

[0026] When welding the four corners of the product's front side, spot welding reinforcement is required first. The control system issues the welding task, and the six-axis welding robot 1 moves along the preset path, precisely positioning the welding head 31 to the weld point. The nozzle is directly facing the center of the weld point. Since the contact area for spot welding is small, to ensure a strong weld, the laser power at the spot weld is reduced to approximately 900W to prevent melting through the product. The spot welding movement speed is also reduced by 8mm / s, and the filler wire amount at the spot weld is increased to ensure a strong weld. When welding large gaps like the liquid storage tank bracket 49, the laser power is increased to approximately 1500W, and the wire feed speed is increased to 22mm / s. An appropriate welding speed is matched to ensure full filler wire at the weld. When welding thinner areas like the lower right bracket 48, the laser power is appropriately reduced to approximately 1kW, and the wire feed speed is reduced to 6mm / s. By matching an appropriate welding speed, a strong, full, and aesthetically pleasing weld is ensured.

[0027] During reverse welding of the product, the six-axis welding robot 1 moves the welding head 31 to the starting point of the weld, activates the shielding gas in advance to expel air from the weld area and prevent oxidation of the molten pool, triggers laser output, and focuses a high-power density laser beam onto the workpiece surface, instantly melting the base material to form a molten pool. Simultaneously, the wire feeding mechanism 33 is started. According to different states of the welded joint, the laser power, wire feeding speed, speed of the six-axis welding robot 1, and the matching parameters of the welding wire and laser at the welding end are adjusted to ensure full filler wire and a smooth finish at the weld.

[0028] In this embodiment, the mounting plate 35 is provided with an assembly interface for mounting the welding head 31 and the wire feeder 33. The position of the assembly interface matches the mounting surface of the flange plate 36 of the six-axis welding robot.

[0029] In this embodiment, the welding fixture 4 includes a dead stop limit block 41, a quick clamp 42, a fixture base plate 43, a contour support structure 45, a manual valve 46, a cylinder pushing structure 47, and a lower right bracket 48. The product body is fixed by the dead stop limit block 41 and the quick clamp 42. The dead stop limit block 41 is installed on the fixture base plate 43. The fixture base plate 43 is connected and fixed into a whole by the fixture connecting strip 44. The front and rear positions of the lower right bracket 48 are positioned by the contour support structure 45.

[0030] The operator activates the tooling assembly via manual valve 46, ensuring a closer fit between the brackets on the product and the manifold of the automotive air conditioning condenser.

[0031] In this embodiment, the manual valve 46 controls the cylinder to push the structure 47, thereby ensuring that the welding bracket is tightly fitted to the product body, and the tooling base plate 43 is provided with a liquid storage tank bracket 49.

[0032] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0033] During operation, the operator first places the product body and welding parts in the designated position of the welding fixture 4, activates the manual valve 46 to fix the product position, and then starts the equipment by pressing the touch screen button after exiting the equipment enclosure. The motor drives the cam divider 21 to rotate the welding fixture to the welding station 8, waiting for welding.

[0034] Secondly, after receiving the instruction, the six-axis welding robot 1 turns on the protective gas in advance to expel the air in the weld area, precisely positions the welding head 31 to the weld point, with the nozzle facing the center of the weld point, triggers laser output, instantly melts the base material to form a molten pool, and simultaneously starts the wire feeding mechanism 33. According to the different states of the product welding connection, the welding laser power, wire feeding speed, welding six-axis robot speed, and welding wire and laser matching parameters at the welding end are adjusted to ensure full wire filling at the weld. The servo motor 22 drives the tooling base frame to rotate 180°, and the six-axis welding robot 2 drives the welding head 31 to weld the bracket on the opposite side. After the welding is completed, the robot returns to the safe position, and the tooling base frame rotates 180° again.

[0035] Then, the motor-driven cam divider 21 rotates the welding fixture 4 to the loading / unloading station 7. The manual valve 46 is manually turned to release the fixture cylinder. The welded product is placed on the logistics turnover vehicle. Then the loading stage steps are repeated. At the same time, the welding station 8 is synchronously welding the product on the fixture 4.

[0036] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0037] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding, characterized in that: The system includes a dual six-axis welding robot (1), a control cabinet (5), a safety fence (6), a loading and unloading station (7), a welding station (8), and a welding mechanism. The welding mechanism includes: A dual-station positioner (2) is set on the opposite side of the six-axis welding robot (1). The dual-station positioner (2) is equipped with a rotary servo (22) and a cam divider (21), which are connected to the control system through circuits. The cam divider (21) realizes planar rotation, so that loading and unloading and welding are carried out simultaneously. The servo reducer (22) realizes axial rotation. The slewing bearing (23) makes the tooling table (25) set on both sides of the cam divider (21) rotate 180 degrees. Welding assembly (3) is installed at the execution end of the six-axis welding robot (1); Welding fixture (4) is set on the dual-position positioner (2).

2. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 1, characterized in that: The dual-station positioner (2) also includes a positioner frame (26). The cam divider (21) is fixed to the ground by a mounting base (24). The servo reducer (22) and the rotary bearing (23) are mounted on the positioner frame (26). The positioner frame (26) is fixed to the cam divider (21) by a connecting plate. The tooling table (25) is fixed to the servo reducer (22) by a rotating connecting plate (28), so that the table can rotate 180 degrees.

3. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 2, characterized in that: The tooling table (25) has reserved positioning pin holes and threaded holes to enable quick change of welding tooling (4).

4. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 2, characterized in that: The positioning pin holes and threaded holes provided on the tooling table (25) are symmetrically distributed and correspond to the positioning pins and mounting holes at the bottom of the welding tooling (4).

5. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 1, characterized in that: The welding assembly (3) includes a welding head (31), a laser (32), a wire feeder (33), a water chiller (34), a mounting plate (35), and a wire feed gun (37). The wire feed gun (37) is installed below the welding head (31). The welding head (31), the wire feeder (33), and the mounting plate (35) are connected. The laser (32) and the water chiller (34) are both installed on the welding station (8). The wire feeder (33) pushes the welding wire to achieve speed-adjustable wire feeding. The mounting plate (35) is connected to the flange plate (36) of the six-axis welding robot.

6. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 5, characterized in that: The mounting plate (35) is provided with an assembly interface for mounting the welding head (31) and the wire feeder (33), and the position of the assembly interface matches the mounting surface of the flange plate (36) of the six-axis welding robot.

7. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 1, characterized in that: The welding fixture (4) includes a dead stop limit block (41), a quick clamp (42), a fixture base plate (43), a contour support structure (45), a manual valve (46), a cylinder pushing structure (47), and a lower right bracket (48). The product body is fixed by the dead stop limit block (41) and the quick clamp (42). The dead stop limit block (41) is installed on the fixture base plate (43). The fixture base plate (43) is connected and fixed into a whole by the fixture connecting strip (44). The front and rear positions of the lower right bracket (48) are positioned by the contour support structure (45).

8. The robotic welding process equipment for automotive air conditioning condensers based on laser filler wire welding according to claim 7, characterized in that: The manual valve (46) controls the cylinder pushing structure (47) to ensure that the welding bracket is tightly fitted to the product body, and the tooling base plate (43) is provided with a liquid storage tank bracket (49).

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