Robotic high-efficiency automated welding structure and apparatus thereof

Abstract

This invention provides a highly efficient automated welding structure for robots, relating to the field of welding equipment technology. It includes: a main frame structure with a slide rail at its bottom; a support and pressure application component slidably mounted on the slide rail for supporting and clamping a cylindrical workpiece from both sides and applying a centripetal force to the workpiece to cause radial contraction; a positioning support component mounted on the main frame structure, including a liftable calibration plate for insertion into the weld gap of the cylindrical workpiece before welding to calibrate and position the weld; and a welding execution component located above the positioning support component and connected to the main frame structure for automated welding of the calibrated weld after the calibration plate is withdrawn. This invention, through the mechanical alignment of the calibration plate and the centripetal pressure of the support and pressure application component, can automatically eliminate weld gaps and ensure weld alignment accuracy, thereby improving welding quality and automated operation efficiency.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to a robotic high-efficiency automated welding structure and device. Background Technology

[0002] Currently, in the furniture manufacturing industry, metal furniture occupies a significant market share due to its high strength, durability, and modern aesthetics. This is especially true for tables, chairs, bed frames, cabinets, and office furniture, which primarily use steel tubing and profiles for their components; welding is extensively employed in their production for connection and assembly. Traditionally, welding of these metal furniture components relied heavily on manual labor, using methods such as gas shielded welding or resistance welding for spot or continuous welding. However, manual welding not only demands high skill levels from workers and involves significant labor intensity, but also suffers from poor weld quality due to human factors, resulting in inconsistent quality and low production efficiency. This makes it difficult to meet the rapidly evolving demands of the modern furniture industry for large-scale, standardized, and personalized customization.

[0003] With advancements in automation technology, robotic automated welding systems have begun to be introduced for welding metal components in the furniture industry. These systems typically consist of industrial robots, welding power sources, and basic tooling platforms, enabling them to perform repetitive welding operations on standard components such as table legs, chair frames, and bed crossbeams according to preset programs. Compared to manual welding, robotic welding significantly improves production efficiency and the consistency of weld appearance, reduces labor costs to some extent, and drives the transformation of metal furniture production towards automation.

[0004] However, the high-efficiency automated welding technology currently applied in the furniture industry still has limitations in practical applications. Specifically, existing welding fixtures can typically only provide simple radial clamping and support for the shape of pipes or profiles. Since most furniture metal parts are made from thin-walled steel pipes through processes such as blanking, bending, and stamping, accumulated tolerances and residual stresses are easily generated during the early processing stages. When welding multiple parts together, especially during the welding of long or circumferential welds (such as the connection between chair back rings and table leg cross braces), stress release and heat input can easily cause misalignment or gaps at the joints, resulting in inconsistent weld gaps. This not only affects the stability and aesthetics of the weld formation but may also cause quality problems such as burn-through or incomplete welds. Furthermore, under the existing automated production model, the alignment and adjustment of welds at the joints of parts often still requires manual intervention or complex mechanical positioning, which not only prolongs the auxiliary time but also makes it difficult to guarantee high-precision positioning requirements, becoming a key bottleneck restricting the furniture industry from achieving efficient, high-quality, fully automated welding production. Summary of the Invention

[0005] The purpose of this invention is to provide a robotic, highly efficient, automated welding structure and apparatus to solve the technical problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A robotic high-efficiency automated welding structure includes: a main frame structure with a slide rail at its bottom; a support and pressure application component slidably mounted on the slide rail for supporting and clamping a cylindrical workpiece from both sides and applying a centripetal force to the cylindrical workpiece to cause it to contract radially; a positioning support component mounted on the main frame structure, including a liftable calibration plate for inserting into the weld gap of the cylindrical workpiece before welding to calibrate and position the weld; and a welding execution component mounted above the positioning support component and connected to the main frame structure for automatically welding the calibrated and aligned weld after the calibration plate is withdrawn.

[0008] Based on the above technical solutions, the present invention also provides the following optional technical solutions:

[0009] In one alternative approach: a centripetal force is applied to the cylindrical workpiece using a support and pressure-applying assembly, actively closing the weld gap caused by stress release. A liftable calibration plate serves as a precise physical reference for positioning, ensuring accurate alignment of the plates on both sides of the weld. This solves the problem that traditional tooling can only passively clamp the workpiece, failing to eliminate the effects of deformation and stress on the cylindrical workpiece. It provides a precise and consistent weld gap for subsequent automated welding, significantly improving the stability and consistency of welding quality.

[0010] In one alternative embodiment, the positioning support assembly further includes: a support plate for supporting the inner wall of the arc apex of the cylindrical workpiece before welding; a lower support body, which is a hollow structure, with one end fixedly connected to the main frame structure, and the support plate located on its top; and a insertion drive unit, located on the lower support body and connected to the bottom of the calibration substrate, for driving the calibration substrate to move vertically between a calibration position extending out of the support plate and an avoidance position retracted into the lower support body. This design allows the calibration substrate to be quickly removed after positioning, avoiding interference with the welding process, and features a compact structure and reliable operation.

[0011] In one alternative embodiment, the insertion drive unit includes: an insertion shaft rotatably mounted on the lower support body; an insertion motor whose output end is connected to the insertion shaft; at least one insertion gear mounted on the insertion shaft; and at least one insertion rack located at the end of the calibration substrate extending into the lower support body and meshing with the insertion gear. The use of rack and pinion transmission provides high control precision and fast response, ensuring that the calibration substrate accurately reaches the preset position.

[0012] In one alternative embodiment, the supporting and pressure-applying assembly includes: a base portion slidably mounted on the slide rail; two symmetrically arranged roller components mounted on the base portion for rolling support of the cylindrical workpiece; and a pressure-applying drive component mounted on the base portion and connected to the two roller components for driving the two roller components to move synchronously towards or away from each other. By moving the symmetrical roller components towards each other, uniform radial pressure can be applied to the cylindrical workpiece, effectively closing the longitudinal weld seam. Simultaneously, the rolling support method facilitates the movement and rotation of the cylindrical workpiece.

[0013] In one alternative embodiment, the roller assembly includes: a sliding base slidably disposed on the base portion; elastic telescopic arms disposed at both ends of the sliding base; and a pressure roller, both ends of which are rotatably connected to the top of the corresponding elastic telescopic arms. The elastic telescopic arms can adapt to minute changes in the diameter of the cylindrical workpiece, providing flexible support, avoiding damage to the cylindrical workpiece caused by rigid clamping, and ensuring uniform pressure.

[0014] In one alternative embodiment, the pressure driving component includes: a pressure motor fixed to the base, with a drive gear at its output end; two connecting arms, one end of which is fixedly connected to the two sliding bases respectively; and two pressure gears, respectively located at the other end of the two connecting arms and meshing with the drive gear. Using a single motor to synchronously drive the two idler roller components via gear transmission results in a simple structure, good synchronization, and ensures balanced pressure application.

[0015] In one alternative embodiment, the welding execution assembly includes: an upper base plate connected to the top of the main frame structure via at least one pressing cylinder, with a welding port in its center; two sets of key-pressing units disposed along the side of the welding port at the bottom of the upper base plate, used to press down and conform to the arc-shaped apex surface of the cylindrical workpiece, and generate sensing signals for determining the length of the cylindrical workpiece and the position of the weld; a welding execution body movably disposed on the upper base plate, having a welding torch that can pass through the welding port; and an axial drive unit connected to the welding execution body for driving it to move along the welding port. The key-pressing unit not only presses the cylindrical workpiece before welding to prevent welding deformation, but also accurately identifies the length of the cylindrical workpiece and the start and end points of the weld by sensing the number of pressed keys, achieving intelligent adaptive welding.

[0016] In one alternative embodiment: the upper substrate has a downwardly bent portion near the edge of the welding port; the key clamping unit includes: multiple guide posts, inclined and fixedly connected to the bent portion; multiple key clamping blocks, respectively sleeved on the ends of each guide post and movable along the axial direction of the guide post; and a return spring, sleeved on the guide post, with its two ends abutting against the bent portion and the key clamping blocks respectively. The inclined guide posts and movable key clamping blocks can better conform to the surface of the arc-shaped cylindrical workpiece, ensuring the clamping effect and the accuracy of signal detection.

[0017] In one alternative embodiment, the axial drive unit includes: a lead screw rotatably mounted on the upper substrate and helically connected to the welding execution body; a guide rod fixedly mounted on the upper substrate and slidingly engaged with the welding execution body; and a drive motor, the output end of which is connected to one end of the lead screw. The lead screw drive provides high-precision linear motion, ensuring the welding torch travels stably along the weld seam and guaranteeing welding quality.

[0018] The present invention also provides a robotic high-efficiency automated welding device, which includes the robotic high-efficiency automated welding structure as described in any of the preceding claims. This device integrates all the advantages of the aforementioned welding structures, enabling efficient, high-precision, and high-quality automated welding of cylindrical workpieces.

[0019] By adopting the above technical solution, the present invention has the following beneficial effects:

[0020] 1. Adaptive weld calibration significantly improves weld formation quality.

[0021] This invention, by setting up a liftable calibration base plate and using a supporting and pressurizing component to apply centripetal force to a cylindrical workpiece, can force the two sides of the weld seam of metal furniture components (such as chair frame rings and table leg connecting tubes) to converge towards the center and precisely fit against the side of the calibration base plate. This design effectively eliminates the uneven weld seam gaps and misalignment caused by springback stress and accumulated tolerances generated in previous processes such as bending and stamping of thin-walled tubes. When the calibration base plate is removed, the two sides of the weld seam can still maintain a tight fit, providing a uniform bevel gap for subsequent automated welding, fundamentally ensuring the weld penetration and aesthetic appearance, and solving the industry problem of easy weld penetration or incomplete weld penetration in thin-walled metal furniture parts.

[0022] 2. Fully automated operation significantly improves production efficiency.

[0023] This solution integrates automatic weld calibration and welding functions. During the process of transporting furniture components to the welding station, the supporting and pressure-applying component automatically sends the top of the weld to the calibration substrate for mechanical alignment, completely eliminating the tedious operation of traditional manual marking or manual adjustment of the weld and greatly shortening the auxiliary time. At the same time, the welding execution component can automatically identify the start and end positions of the weld and adjust the welding stroke according to the axial length of the cylindrical workpiece through the piano key clamping unit. This realizes unmanned and automated operation of the entire process from loading, automatic alignment, precision welding to unloading, which significantly improves the cycle time and capacity of large-scale metal furniture production.

[0024] 3. Built-in dynamic support structure effectively suppresses welding deformation.

[0025] The calibration base plate is integrated into the internal cavity of the lower support body and adopts a lifting structure design. After completing the weld alignment task, it can be quickly retracted downwards, providing ample operating space for the welding torch and completely avoiding motion interference between the welding torch and the calibration mechanism during welding. At the same time, the arc-shaped support plate continuously provides stable support to the inner wall of the arc apex of the cylindrical workpiece throughout the welding process, effectively enhancing the structural rigidity of thin-walled furniture components under high-temperature welding conditions, greatly reducing welding deformation caused by heat input, and ensuring the dimensional accuracy and flatness of the finished furniture.

[0026] 4. In conventional thinking, after the calibration reference is removed, the workpiece will naturally spring back due to elastic recovery, and the weld gap will widen again. However, the control system of this invention breaks this technical bias. By actively maintaining the centripetal force after the calibration substrate is removed, the weld is forced to remain tightly fitted even without a reference. At the same time, the threshold criterion of the pressure sensor is used to realize the machine's autonomous decision on "alignment" rather than the traditional manual or time estimation.

[0027] 5. The control system analyzes the pressure-time curve characteristics during the bonding process to identify the differences in residual stress caused by the bending and stamping processes in different batches of workpieces, and dynamically adjusts the application rate of centripetal force and the holding time; this enables the control system to automatically adapt to the tolerance fluctuations of the previous process without the need for manual readjustment.

[0028] 6. During the welding process, heat input can cause local expansion of the workpiece, thereby increasing the weld gap. This control system creatively introduces a heat input compensation subunit, which dynamically fine-tunes the centripetal force based on real-time welding parameters to counteract the effects of thermal expansion and ensure that the bevel gap of the entire weld is uniform. This solves the problem of gap stability control under high-temperature welding conditions.

[0029] 7. By controlling the number and position of the pressed piano key blocks in the piano key clamping unit, the control system automatically identifies the workpiece length and the start and end positions of the weld, and matches the corresponding welding process parameters; this non-contact or low-cost contour recognition method avoids the high cost and susceptibility to arc light interference of traditional vision sensors. Attached Figure Description

[0030] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the overall structure of a robot-driven, highly efficient, automated welding structure according to one embodiment of the present invention.

[0032] Figure 2 This is a schematic diagram of a robot's efficient automated welding structure for removing the main frame structure, according to one embodiment of the present invention.

[0033] Figure 3 This is a schematic diagram of one view of the positioning support component in one embodiment of the present invention.

[0034] Figure 4 This is a schematic diagram of the positioning support component from another perspective in one embodiment of the present invention.

[0035] Figure 5 This is a schematic diagram of the supporting and pressure-applying component structure in one embodiment of the present invention.

[0036] Figure 6 This is a schematic diagram of the welding execution component structure in one embodiment of the present invention.

[0037] Figure 7 for Figure 6 Enlarged structural diagram at point A in the middle.

[0038] Reference numerals in the attached drawings: Main frame structure 100, slide rail 110, support and pressure assembly 200, base part 210, sliding base 220, pressure roller 230, elastic telescopic support arm 240, pressure motor 250, connecting support arm 260, loading and unloading cylinder 270, pressure gear 280, drive gear 290, cylindrical workpiece 300, welding execution assembly 400, upper base plate 410, welding execution main body moving motor 420, downward pressure cylinder 430, lead screw 440, 450, guide rod 460, piano key clamping unit 470, piano key pressure block 471, guide post 472, guide post 472, bending part 480, positioning support assembly 500, support plate part 510, calibration base plate 520, lower support main body 530, insertion and shifting shaft 540, insertion and shifting gear 550, insertion and shifting motor 560, insertion and shifting rack 570. Detailed Implementation

[0039] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings and specific embodiments. The described embodiments are merely some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0040] Example 1

[0041] like Figure 1 and Figure 2 As shown, this embodiment provides a highly efficient automated welding structure for robots, mainly used to solve the problems of misaligned weld seams and uneven gaps in the automated welding process of cylindrical metal workpieces (such as steel furniture legs, rolled handrails, etc.). The structure mainly includes: a main frame structure 100, a support and pressure application component 200, a positioning support component 500, and a welding execution component 400.

[0042] The main frame structure 100 serves as the supporting skeleton for the entire equipment. It has a slide rail 110 at the bottom and a frame at the top for installing the welding execution component 400.

[0043] The supporting and pressure-applying assembly 200 is slidably mounted on the slide rail 110 and can move along its length. This assembly is not only used to support the cylindrical workpiece 300 during loading and unloading, but its more core function is to apply centripetal force to the cylindrical workpiece 300 from both sides during the welding preparation stage, causing it to contract radially, thereby actively closing the weld gap caused by residual stress or deformation.

[0044] The positioning support assembly 500 is fixedly mounted on the main frame structure 100 and located at the welding station. Its core component is a liftable calibration base plate 520. During the welding preparation stage, the calibration base plate 520 rises and is inserted into the weld gap of the cylindrical workpiece 300, providing a precise physical alignment reference for the plates on both sides of the weld.

[0045] The welding execution component 400 is positioned directly above the positioning support component 500 and connected to the top of the main frame structure 100. After the calibration base plate 520 completes its mission and descends for removal, this component is responsible for the automated welding of the precisely aligned weld seams.

[0046] Example 2

[0047] This embodiment is based on Embodiment 1, and the positioning support component 500 is further specified.

[0048] like Figure 2 , Figure 3 , Figure 4 As shown, the positioning support assembly 500 includes a support plate 510, a lower support body 530, a calibration base plate 520, and an insertion drive unit.

[0049] The lower support body 530 is a hollow structure, with one end fixedly connected to the main frame structure 100. The support plate 510 is located at the top of the lower support body 530 and is arc-shaped, matching the curvature of the inner wall of the cylindrical workpiece 300. It provides stable internal support by internally supporting the arc-shaped apex area of ​​the cylindrical workpiece 300 before welding. The calibration substrate 520 is vertically positioned, with its top passing through a pre-set opening in the middle of the support plate 510 and its bottom extending downwards into the internal cavity of the lower support body 530. Preferably, pressure sensing plates (not shown in the figure) are provided on both sides of the calibration substrate 520 to detect whether the plates on both sides of the weld are tightly bonded.

[0050] The insertion drive unit is mounted on the lower support body 530 and connected to the bottom of the calibration substrate 520. In a preferred embodiment, the insertion drive unit includes an insertion shaft 540, an insertion motor 560, at least one insertion gear 550, and at least one insertion rack 570. The insertion shaft 540 is rotatably mounted on the lower side of the lower support body 530, with one end connected to the output end of the insertion motor 560. The insertion gear 550 is fixed to the insertion shaft 540. The insertion rack 570 is vertically disposed at the end of the calibration substrate 520 that extends into the lower support body 530 and meshes with the insertion gear 550. When the insertion motor 560 operates, it drives the insertion shaft 540 and the insertion gear 550 to rotate. Through the meshing transmission of the gear and rack, the calibration substrate 520 can be precisely driven to rise (calibrate position) or fall (avoidance position) in the vertical direction.

[0051] Example 3

[0052] This embodiment is based on embodiment 1 or 2, and the supporting pressure component 200 is further specified.

[0053] like Figure 1 , Figure 2 , Figure 5 As shown, the supporting and pressure-applying assembly 200 includes a base portion 210, two symmetrically arranged idler roller components, a pressure-applying drive component, and a loading and unloading cylinder 270.

[0054] The base portion 210 is slidably mounted on the slide rail 110 via a slider. The cylinder body of the loading / unloading cylinder 270 is fixed to the main frame structure 100, and its piston rod is connected to the side of the base portion 210 to drive the entire supporting and pressure-applying assembly 200 to move between the loading / unloading position and the welding position.

[0055] The roller assembly includes a sliding base 220, elastic telescopic arms 240, and a pressure roller 230. The sliding base 220 is slidably mounted on a guide rail (such as 710, which can be understood as a guide rail on the base) on the upper surface of the base portion 210. Each sliding base 220 has elastic telescopic arms 240 at both ends, and these arms may contain springs or cylinders to provide telescopic and cushioning functions. The two ends of the pressure roller 230 are rotatably connected to the tops of the elastic telescopic arms 240 on both sides, allowing it to rotate freely, thereby supporting and allowing the cylindrical workpiece 300 to roll on it.

[0056] The pressure-driving component is used to drive the two sliding bases 220 to move synchronously towards or away from each other. In a preferred embodiment, the pressure-driving component includes a pressure motor 250 and two connecting arms 260. The pressure motor 250 is fixed to the upper surface of the base portion 210, and a drive gear 290 is mounted on its output end. One end of each of the two connecting arms 260 is fixedly connected to the two sliding bases 220, and the other end extends to the vicinity of the pressure motor 250, where a pressure-applying gear 280 is rotatably mounted. Both pressure-applying gears 280 mesh with the drive gear 290. When the pressure motor 250 is started, the drive gear 290 rotates, driving the two pressure-applying gears 280 to rotate in opposite directions, thereby driving the two sliding bases 220 and their pressure rollers 230 to move towards or away from each other via the connecting arms 260. When moving towards each other, the two pressure rollers 230 apply pressure to the sidewall of the cylindrical workpiece 300, achieving centripetal pressure.

[0057] Example 4

[0058] This embodiment is based on any one of embodiments 1-3, and the welding execution component 400 is further specified.

[0059] like Figure 1 , Figure 2 , Figure 6 , Figure 7 As shown, the welding execution assembly 400 includes an upper base plate 410, a key pressing unit 470, a welding execution body 420, and an axial drive unit.

[0060] The upper substrate 410 is connected to the top frame of the main frame structure 100 via at least two downward pressure cylinders 430. The downward pressure cylinders 430 can drive the entire upper substrate 410 and its components to rise and fall as a whole. A long strip-shaped welding port is provided in the middle of the upper substrate 410 to allow the welding torch to pass through.

[0061] The key clamping unit 470 is divided into two groups, respectively arranged along the long sides of the welding port. For example... Figure 7 As shown, in a preferred embodiment, the upper substrate 410 has a downwardly bent portion 480 near the edge of the welding port. The key clamping unit 470 includes multiple key clamping blocks 471, multiple guide posts 472, and multiple return springs 473. Each guide post 472 is arranged along the inclined direction of the bent portion 480 and is fixedly connected to the bent portion 480. The key clamping block 471 is sleeved on the lower end of the guide post 472 and can slide along the axial direction of the guide post 472. The return spring 473 is sleeved on the guide post 472, with its two ends abutting against the bent portion 480 and the key clamping block 471, respectively, so that the key clamping block 471 maintains a downwardly extending tendency. When the upper substrate 410 is pressed down, the multiple key clamping blocks 471 will sequentially contact and press against the arcuate surface of the cylindrical workpiece 300. Each key pressure block 471 or guide post 472 can be integrated with a displacement sensor or pressure sensor. When a key pressure block 471 is lifted, a sensing signal is generated. By analyzing the number and position of the triggered key pressure blocks 471, the control system can accurately determine the axial length of the cylindrical workpiece 300 and the start and end positions of the weld.

[0062] The welding execution body 420 (including a welding torch and related wire feeding mechanism, etc.) is movably disposed on the upper surface of the upper substrate 410. The axial drive unit is connected to the welding execution body 420 and is used to drive it to move along the length direction of the welding port (i.e., the axial direction of the cylindrical workpiece 300). In a preferred embodiment, the axial drive unit includes a lead screw 440, a guide rod 460, and a drive motor 450. The lead screw 440 is rotatably mounted on the upper substrate 410 and forms a helical transmission connection with a threaded block at the bottom of the welding execution body 420. The guide rod 460 is fixedly mounted on the upper substrate 410 and slides through the welding execution body 420, serving a guiding function. The output end of the drive motor 450 is connected to one end of the lead screw 440. When the drive motor 450 is working, the lead screw 440 rotates, driving the welding execution body 420 and the welding torch on it to move precisely along the guide rod 460.

[0063] Working principle of the embodiments of the present invention

[0064] The following describes a complete working cycle of the robot's highly efficient automated welding structure in conjunction with the above embodiments:

[0065] Initial State and Loading: The equipment is in standby mode. At this time, the loading / unloading cylinder 270 retracts, pulling the supporting pressure assembly 200 to the loading position at the end of the slide rail 110. The operator or robot lifts the cylindrical workpiece 300 to be welded (e.g., a steel table leg made of rolled steel plate) onto the two pressure rollers 230. Due to the action of the elastic telescopic support arm 240, the pressure rollers 230 can adapt to the diameter of the cylindrical workpiece 300, stably supporting it.

[0066] Transfer and Internal Support: The loading / unloading cylinder 270 extends, pushing the supporting and pressure-applying assembly 200 and the cylindrical workpiece 300 on it along the slide rail 110 towards the welding station. When the cylindrical workpiece 300 moves directly below the welding execution assembly 400, the support plate 510 of the positioning support assembly 500 is precisely inserted into the interior of the cylindrical workpiece 300 and fits tightly against its inner arc apex wall, providing internal support. At this time, the longitudinal seam to be welded on the cylindrical workpiece 300 is located exactly at the arc apex, and the calibration substrate 520 is directly opposite the inner side of the weld seam.

[0067] Pressure Application and Fine Alignment: The control system activates the pressure motor 250, which, through the transmission of the drive gear 290 and the pressure gear 280, drives the two sliding bases 220 to move synchronously towards each other. The two pressure rollers 230 then approach, applying uniform radial pressure to the sidewalls of the cylindrical workpiece 300. Under pressure, the cylindrical workpiece 300 undergoes slight elastic deformation, gradually reducing any potential weld gap until the edges of the plates on both sides of the weld are tightly fitted and abut against the two sides of the calibration base plate 520. The pressure sensor on the calibration base plate 520 provides feedback signals, confirming that the weld has been precisely positioned and aligned.

[0068] Welding Execution: After weld alignment, the welding process begins. First, the lowering cylinder 430 extends, driving the upper base plate 410 to descend until multiple key-pressing blocks 471 of the key-pressing unit 470 press against the arc-shaped surface of the cylindrical workpiece 300. The control system analyzes the number and position of the pressed-down key-pressing blocks 471 to accurately confirm the length of the cylindrical workpiece 300 and the precise position of the weld. After confirmation, the insertion motor 560 starts, driving the calibration base plate 520 to descend rapidly and retract completely into the lower support body 530, making room for welding. Subsequently, the drive motor 450 starts, driving the lead screw 440 to rotate, causing the welding execution body 420 to move along the guide rod 460. During the movement, the welding torch performs continuous, high-quality automated welding of the weld below through the welding port of the upper base plate 410.

[0069] Unloading and Resetting: After welding is completed, the welding execution body 420 stops welding and resets, the pressing cylinder 430 retracts, driving the upper substrate 410 to rise. The insertion motor 560 reverses, driving the calibration substrate 520 to rise and reset. The pressure motor 250 reverses, causing the two pressure rollers 230 to release their grip on the cylindrical workpiece 300. Finally, the unloading cylinder 270 retracts, moving the supporting pressure assembly 200 and the finished cylindrical workpiece 300 on it to the unloading position, awaiting unloading.

[0070] Example 5

[0071] This embodiment provides a robotic high-efficiency automated welding device, which includes the robotic high-efficiency automated welding structure described in any one of embodiments 1-4 above. Furthermore, the device may also include a robotic arm for automatic loading and unloading, a control system for controlling the coordinated operation of various components, and auxiliary equipment such as a welding machine and a wire feeder. By integrating these components, a complete production unit capable of automating the entire welding process from blank loading to finished product unloading is formed.

[0072] A robotic high-efficiency automated welding device further includes a control system, the control system comprising:

[0073] The weld seam calibration control unit controls the supporting pressure assembly 200 to apply radial centripetal force to the cylindrical workpiece 300, causing the workpiece to elastically deform and bring its two sides of the weld seam towards the center. It also controls a liftable calibration plate 520 to rise into the weld seam gap so that the two sides of the weld seam can be abutted after being brought together. The pressure sensing plate set on the calibration plate 520 detects the abutment pressure in real time. When the detected pressure value reaches the preset abutment threshold, it is determined that the weld seam gap has been eliminated and the two sides are accurately aligned, and an alignment completion signal is output.

[0074] The pressure holding welding control unit, in response to the alignment completion signal, controls the calibration substrate 520 to descend and retract, and controls the supporting pressure component 200 to maintain radial centripetal force so that the two sides of the weld remain tightly fitted in the absence of a physical reference to form a uniform bevel gap. Then, it controls the welding execution component 400 to perform welding along the weld trajectory.

[0075] The joint calibration control unit is further configured to:

[0076] The loading and unloading cylinder 270 is controlled to move the supporting and pressure-applying assembly 200, which carries the cylindrical workpiece 300, to the welding station;

[0077] The control insertion motor 560 drives the calibration substrate 520 to rise to a position opposite to the inside of the weld;

[0078] The pressure motor 250 is controlled to drive the two pressure rollers 230 to move synchronously towards each other in a linear or segmented manner, thereby applying a gradually increasing radial centripetal force to the side wall of the workpiece.

[0079] The feedback pressure value of the pressure sensing sheet is continuously sampled. When the value reaches the preset bonding threshold for the first time, the current position of the pressure motor 250 is immediately locked, and the pressure value at that moment is recorded as the pressure holding target value.

[0080] The pressure-holding welding control unit is further configured to:

[0081] After receiving the alignment completion signal, the control insertion motor 560 drives the calibration substrate 520 to descend completely below the support surface of the support plate portion 510;

[0082] The pressure motor 250 is controlled to adjust the output torque in a closed-loop manner so that the real-time feedback value of the pressure sensor is maintained within the allowable error range of the pressure holding target value, in order to compensate for gap fluctuations in the workpiece caused by residual stress release or welding heat input.

[0083] The control cylinder 430 presses the key pressing unit 470 against the surface of the workpiece arc, and automatically identifies the axial length of the workpiece and the start and end positions of the weld according to the number and position of the pressed key blocks 471.

[0084] The control drive motor 450 drives the welding execution body 420 to move along the identified weld seam trajectory and starts the welding gun to perform welding.

[0085] The control system is configured to execute the following control phases sequentially:

[0086] Phase 1, workpiece positioning and reference insertion: control the supporting and pressure-applying assembly 200 to transport the cylindrical workpiece 300 to the welding station, and control the calibration plate 520 to rise to the inside of the weld.

[0087] Phase 2, Active Seam ...

[0088] Phase 3, Reference Removal and Pressure Maintenance: Control the calibrator substrate 520 to descend and be removed, while maintaining radial centripetal force to keep the weld gap uniform and consistent in the absence of a physical reference.

[0089] Phase 4, Adaptive Welding: Identify the workpiece contour and weld trajectory, and control the welding torch to complete the welding along the trajectory;

[0090] Phase 5, Reset and Unloading: Sequentially control welding to stop, welding execution component 400 to lift, radial centripetal force to release, calibration substrate 520 to reset, and support and pressure component 200 to remove the finished workpiece.

[0091] The control system also includes:

[0092] The front-end error compensation module records the pressure-time curve of the pressure sensor during the joint calibration control unit. Based on the slope and peak characteristics of the curve, it identifies the direction and magnitude of the residual stress generated by the bending and stamping processes on the workpiece. Based on this, it dynamically adjusts the application rate of the centripetal force and the holding time to actively adapt to the front-end tolerance fluctuations of different batches of workpieces.

[0093] During the seam calibration control unit's execution, if the pressure values ​​on the left and right sides of the pressure sensing sheet show asymmetrical deviation, or if the final bonding pressure value exceeds the preset standard threshold range, the defect prediction module determines that the workpiece has serious misalignment or uncorrectable deformation defects and outputs a rejection command or alarm signal.

[0094] The heat input compensation subunit acquires the welding current, arc voltage and welding speed of the welding torch in real time during the welding process, calculates the expected thermal expansion caused by the heat input, and dynamically fine-tunes the magnitude of the radial centripetal force to counteract the trend of increased weld gap caused by thermal expansion and ensure consistent penetration depth.

[0095] The adaptive teaching module analyzes the distribution sequence of the pressed key blocks 471 in the key pressing unit 470, generates the contour point cloud of the workpiece arc top, and matches it with the pre-stored standard model database to automatically retrieve the corresponding welding process parameters, including welding current, speed and oscillation amplitude, without the need for manual teaching.

[0096] The control system works in conjunction with the following mechanical structures:

[0097] The supporting and pressure-applying assembly 200 includes a base portion 210 movable along the slide rail 110, two symmetrical pressure rollers 230 driven by a pressure motor 250 through gear transmission, and elastic telescopic support arms 240 respectively connected to the two pressure rollers 230. The elastic telescopic support arms 240 are used to adapt to changes in workpiece diameter.

[0098] The positioning support assembly 500 includes a hollow lower support body 530, an arc-shaped support plate 510 fixed to its top, and a lifting calibration base plate 520 driven by a shift motor 560 through a gear and rack. Pressure sensing plates are provided on both sides of the calibration base plate 520.

[0099] The welding execution assembly 400 includes an upper base plate 410 driven by a downward pressure cylinder 430, a piano key clamping unit 470 mounted on the bottom of the upper base plate 410, and a welding execution body 420 driven by a drive motor 450 via a lead screw.

[0100] In conventional thinking, after the calibration reference is removed, the workpiece will naturally spring back due to elastic recovery, and the weld gap will widen again. However, the control system of this invention breaks this technical bias. By actively maintaining centripetal force after the calibration substrate 520 is removed, it forces the weld to remain tightly fitted even without a reference. At the same time, it uses the threshold criterion of the pressure sensor to realize the machine's autonomous decision on "alignment" rather than the traditional manual or time estimation.

[0101] The control system analyzes the pressure-time curve characteristics during the bonding process to identify the differences in residual stress caused by bending and stamping processes in different batches of workpieces, and dynamically adjusts the application rate of centripetal force and the holding time. This allows the control system to automatically adapt to the tolerance fluctuations of the previous process without the need for manual readjustment.

[0102] During welding, heat input causes local expansion of the workpiece, thereby increasing the weld gap. This control system creatively introduces a heat input compensation subunit, which dynamically fine-tunes the centripetal force based on real-time welding parameters to counteract the effects of thermal expansion and ensure that the bevel gap of the entire weld is uniform. This solves the problem of gap stability control under high-temperature welding conditions.

[0103] By controlling the number and position of the pressed key blocks 471 in the key pressing unit 470, the control system automatically identifies the workpiece length and the start and end positions of the weld, and matches the corresponding welding process parameters. This non-contact or low-cost contour recognition method avoids the high cost and susceptibility to arc light interference of traditional vision sensors.

[0104] In summary, this invention, through the combination of a unique support and pressure component and a liftable calibration base plate, achieves active calibration and precise positioning of weld seams on cylindrical workpieces, solving welding problems caused by workpiece deformation and stress. Combined with an intelligent key-pressing unit and a precise axial drive system, it significantly improves the automation level and quality stability of welding, making it ideal for the large-scale, high-quality production needs of industries such as metal furniture.

[0105] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

Claims

1. Robotic high-efficiency automated welding structures, including: The main frame structure (100) has a slide rail (110) at its bottom. The support and pressure application assembly (200) is slidably disposed on the slide rail (110) for supporting and clamping the cylindrical workpiece (300) from both sides, and for applying a centripetal force to the cylindrical workpiece (300) to cause it to contract radially; A positioning support assembly (500) is provided on the main frame structure (100), which includes a liftable calibration plate (520) for insertion into the weld gap of the cylindrical workpiece (300) before welding to calibrate and position the weld. A welding execution component (400) is disposed above the positioning support component (500) and connected to the main frame structure (100) for automatically welding the aligned weld seam after the calibration substrate (520) is removed.

2. The robot-driven high-efficiency automated welding structure according to claim 1, characterized in that, The positioning support component (500) further includes: The support plate (510) is used to support the inner wall of the arc top of the cylindrical workpiece (300) before welding; The lower support body (530) is a hollow structure, with one end fixedly connected to the main frame structure (100), and the support plate (510) is located on its top; An insertion drive unit is disposed on the lower support body (530) and connected to the bottom of the calibration substrate (520), and is used to drive the calibration substrate (520) to move vertically between the calibration position extending out of the support plate (510) and the avoidance position retracted into the lower support body (530). The insertion / shifting drive unit includes: Insert the pivot (540), which is rotatably mounted on the lower support body (530); The output end of the insertion motor (560) is connected to the insertion shaft (540); At least one insertion gear (550) is provided on the insertion shaft (540); At least one insertion rack (570) is provided at the end of the calibration base plate (520) that extends into the lower support body (530) and meshes with the insertion gear (550).

3. The robot-driven high-efficiency automated welding structure according to claim 1, characterized in that, The supporting pressure assembly (200) includes: The base portion (210) is slidably disposed on the slide rail (110); Two symmetrically arranged roller components are provided on the base part (210) for rolling support of the cylindrical workpiece (300). A pressure drive component is provided on the base part (210) and connected to the two idler roller components, for driving the two idler roller components to move synchronously towards or away from each other; The idler roller component includes: A sliding base (220) is slidably disposed on the base portion (210); Elastic telescopic arms (240) are provided at both ends of the sliding base (220); The pressure roller (230) is rotatably connected at both ends to the top of the corresponding elastic telescopic support arm (240).

4. The robot-driven high-efficiency automated welding structure according to claim 3, characterized in that, The pressurization drive component includes: A pressure motor (250) is fixed on the base (210), and its output end is provided with a drive gear; Two connecting arms (260) are fixedly connected at one end to the two sliding bases (220) respectively; Two pressure gears (280) are respectively located at the other end of the two connecting arms (260) and both mesh with the drive gear.

5. The robot-driven high-efficiency automated welding structure according to claim 1, characterized in that, The welding execution assembly (400) includes: The upper base plate (410) is connected to the top of the main frame structure (100) by at least one downward cylinder (430), and a welding port is provided in the middle of the plate. The key pressing unit (470) is divided into two groups and is disposed on the bottom of the upper substrate (410) along the side of the welding port. It is used to press down and fit the arc top surface of the cylindrical workpiece (300) and generate induction signals for determining the length of the workpiece (300) and the position of the weld. The welding execution body (420) is movably disposed on the upper substrate (410) and has a welding torch that can pass through the welding port; An axial drive unit, connected to the welding execution body (420), is used to drive it to move along the welding port.

6. The robot-driven high-efficiency automated welding structure according to claim 5, characterized in that, The upper substrate (410) has a downwardly bent portion (480) near the edge of the welding port; the key clamping unit (470) includes: Multiple guide posts (472) are inclined and fixedly connected to the bent portion (480); Multiple key pressure blocks (471) are respectively sleeved on the ends of each guide post (472) and can move axially along the guide post (472); A reset spring (473) is sleeved on the guide post (472), with its two ends abutting against the bent part (480) and the piano key pressure block (471) respectively.

7. The robot-driven high-efficiency automated welding structure according to claim 6, characterized in that, The axial drive unit includes: The lead screw (440) is rotatably mounted on the upper base plate (410) and is connected to the welding execution body (420) by a screw drive. The guide rod (460) is fixedly mounted on the upper base plate (410) and slides in cooperation with the welding execution body (420); The drive motor (450) has its output end connected to one end of the lead screw (440).

8. A robotic high-efficiency automated welding device, characterized in that, Including the robotic high-efficiency automated welding structure as described in claim 7, and a control system, the control system comprising: The seam alignment control unit controls the supporting pressure assembly (200) to apply radial centripetal force to the cylindrical workpiece (300), causing the workpiece to shrink its two sides of the weld seam towards the center due to elastic deformation, and controls a liftable calibration plate (520) to rise into the weld seam gap for the shrunken two sides of the weld seam to abut; the pressure sensing plate set on the calibration plate (520) detects the abutment pressure in real time, and when the detected pressure value reaches the preset abutment threshold, it is determined that the weld seam gap has been eliminated and the two sides are accurately aligned, and an alignment completion signal is output; The pressure holding welding control unit, in response to the alignment completion signal, controls the calibration substrate (520) to descend and withdraw, and controls the support pressure assembly (200) to maintain radial centripetal force so that the two sides of the weld remain tightly fitted in the absence of a physical reference to form a uniform bevel gap, and then controls the welding execution assembly (400) to perform welding along the weld trajectory.

9. The high-efficiency automated robotic welding device according to claim 8, characterized in that, The control system also includes: The front-end error compensation module records the pressure-time curve of the pressure sensor during the joint calibration control unit. Based on the slope and peak characteristics of the curve, it identifies the direction and magnitude of the residual stress generated by the bending and stamping processes on the workpiece. Based on this, it dynamically adjusts the application rate of the centripetal force and the holding time to actively adapt to the front-end tolerance fluctuations of different batches of workpieces. During the seam calibration control unit's operation, if the pressure values ​​on the left and right sides of the pressure sensing plate show asymmetrical deviation, or if the final bonding pressure value exceeds the preset standard threshold range, the defect prediction module determines that the workpiece has serious misalignment or uncorrectable deformation defects and outputs a rejection command or alarm signal.

10. The high-efficiency automated robotic welding device according to claim 8, characterized in that, The control system also includes: The heat input compensation subunit acquires the welding current, arc voltage and welding speed of the welding torch in real time during the welding process, calculates the expected thermal expansion caused by the heat input, and dynamically fine-tunes the magnitude of the radial centripetal force to counteract the trend of increased weld gap caused by thermal expansion and ensure consistent penetration depth. The adaptive teaching module analyzes the distribution sequence of the pressed key blocks (471) in the key pressing unit (470), generates the contour point cloud of the workpiece arc top, and matches it with the pre-stored standard model database. It automatically retrieves the corresponding welding process parameters, including welding current, speed and oscillation amplitude, without the need for manual teaching.

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