A welding device for a connection of components and a method of operation thereof

Abstract

The application is suitable for the technical field of welding, and provides a welding device for component connection and a working method thereof.The welding device comprises a workbench, a welding manipulator, a positioning assembly installed on the top of the workbench and used for welding components, and a limiting mechanism sliding on the top of the workbench.The device solves the problem that the butt joint reference surface of the to-be-welded component is poorly fitted, the gap is uneven, and the assembly reference is deviated due to surface flatness defects and size tolerance fluctuations, and further causes welding defects.The device is provided with a blocking pipe mechanism around the four corners of the inner wall of the frame body, the rolling fitting of the wheel body with a tapered part and the edge of the second component reduces the sliding resistance, the micro motion sensor collects data in real time, the control system controls the distance of the two-way cylinder in a closed loop, the wear of the wheel body is compensated, the sliding posture of the component is corrected, the verticality of the vertical sliding of the second component is ensured, the butt joint deviation is avoided, and the butt joint precision of the component and the consistency of the welding operation are improved.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more specifically, to a welding apparatus for component joints and a method of operation thereof. Background Technology

[0002] Welding is a core material connection and forming process in the fields of machinery manufacturing, steel structure processing, and engineering equipment production. Component welding is the process of rigidly fixing and forming multiple independent metal components into one piece through welding. It is a key process that determines the structural strength, shape and position accuracy, and subsequent assembly compatibility of the components. In the production process, the two components to be welded must first be manually aligned, fitted, positioned, and temporarily fixed. Then, the operator holds the welding equipment and welds the butt joint of the two components to complete the welding process of a single component.

[0003] Traditional manual welding methods suffer from problems such as unstable alignment accuracy, low production efficiency, poor weld quality consistency, and high labor intensity. Those skilled in the art have improved the welding process for components. The improved solution adds a contour positioning seat that is perfectly adapted to the shape of the component to be welded. During operation, the two components to be welded are automatically pre-aligned and positioned, and then a multi-axis welding robot automatically completes the entire welding process of the butt weld according to the preset welding program and travel path, thereby improving welding production efficiency.

[0004] However, the improved automated welding solution still has the following problems: In actual mass production, after the components to be welded are processed by previous cutting, stamping, bending and other processes, surface flatness defects, slight deformation of components, and dimensional tolerance fluctuations are inevitable. Components with defects cannot achieve complete fit of the docking reference surface, and uneven docking gaps and assembly reference offsets are very likely to occur, which will lead to defects in the robotic arm welding, such as incomplete penetration, weld penetration, porosity or off-center welding. Even if the welding operation is finally completed, the form and position tolerance of the components will exceed the standard due to the previous deformation and docking deviation, which will directly have an adverse effect on the subsequent whole machine assembly process, and may even result in the finished product being unable to be assembled. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a welding device for component connection and its working method.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a welding device for component connection, comprising a worktable.

[0007] A welding robot, mounted on top of a workbench, is used for welding components.

[0008] A positioning component is installed on the top of the worktable. The positioning component includes a limiting mechanism that slides on the top of the worktable and is used to dock with the first component.

[0009] A conduit assembly is installed on the top of the workbench and is used to vertically guide the second component. The conduit assembly includes a frame set above the limiting mechanism and four sets of tube-blocking mechanisms. The four sets of tube-blocking mechanisms are installed equidistantly around the four corners of the inner wall of the frame. Each set of tube-blocking mechanisms includes a support plate connected to the frame and two wheels. A micro-motion sensor is installed on the top of the support plate and between the two wheels.

[0010] Two sets of first industrial cameras and two sets of second industrial cameras are symmetrically installed on the top of the limiting mechanism. The two sets of first industrial cameras and the two sets of second industrial cameras are equidistantly arranged around the component and are used to photograph the gap between the two components.

[0011] The present invention is further configured such that the conduit assembly includes a vertical frame mounted on the top of the workbench and a horizontal frame connected to the side wall of the vertical frame, the frame being connected to one side of the horizontal frame.

[0012] The invention is further configured such that two brackets slide on the top of the support plate, two wheels are correspondingly arranged with the two brackets, the wheels rotate on the side wall of the corresponding bracket, a bidirectional cylinder is installed on the top of the support plate, the two piston rods of the bidirectional cylinder are connected to the two brackets, and a tapered portion is opened on the opposite side of the two wheels.

[0013] The present invention is further configured such that a protective cover is installed on the top of the support plate, and the micro-motion sensor is installed inside the protective cover.

[0014] The invention is further configured such that a base is mounted on the top of the workbench, a guide rail is mounted on the top of the base, a slide is slidably mounted on the top of the guide rail, the slide slides on the top of the guide rail, a limiting mechanism is mounted on the top of the slide, and a transfer cylinder is also mounted on the top of the base, the piston rod of the transfer cylinder being connected to the limiting mechanism.

[0015] The present invention is further configured such that the limiting mechanism includes lifting cylinders installed on both sides of the slide table, the piston rods of the two lifting cylinders are connected to a top plate, and the two sets of first industrial cameras and the two sets of second industrial cameras are all arranged around the top of the top plate.

[0016] The invention is further configured such that two sets of push-clamp cylinders are symmetrically installed at the bottom of the top plate, the two sets of push-clamp cylinders are arranged opposite each other and the piston rods of both are connected to clamping blocks, two elongated holes corresponding to the clamping blocks are symmetrically opened at the top of the top plate, the clamping blocks pass through the corresponding elongated holes and are used to clamp the side walls of the component in two width directions, a column and a contour piece are connected to the top of the top plate, a gap is provided between the contour piece and the column, a positioning column is connected to the center of the top surface of the contour piece, and the center line of the frame overlaps with the axis of the positioning column.

[0017] The invention is further configured such that a clamping cylinder is installed at the bottom of the top plate, the piston rod of the clamping cylinder is connected to a clamping plate, an elongated hole corresponding to the clamping plate is opened at the top of the top plate, the clamping plate extends to the top of the top plate through the corresponding elongated hole, and is used to clamp the side walls of the component in two length directions.

[0018] The invention is further configured such that two sets of clamping cylinders are installed on one side of the top plate, and the clamping end of the clamping cylinder is used to clamp the top of the component.

[0019] A welding method for component joints, using the welding apparatus for component joints as described above, includes the following steps: S1. Place the first component on top of the limiting mechanism, and use the limiting mechanism to position and lock the first component.

[0020] S2. When the second component is installed, four sets of tube-blocking mechanisms are used to assist in guiding the four edges of the second component. That is, two wheels in each set of tube-blocking mechanisms are in contact with the side wall of the second component, and the side wall of the second component slides on the corresponding wheels to ensure that the second component remains vertical during the downward sliding process.

[0021] S3. During the entire process of the second component sliding through the tube, the position data of the four edges of the second component are detected in real time by the micro-motion sensors in the four sets of tube-blocking mechanisms, and the vertical attitude deviation of the second component and the degree of contact between the corresponding wheel and the side wall of the second component are judged simultaneously.

[0022] S4. After the second component is in place, two sets of first industrial cameras and two sets of second industrial cameras arranged around it will take pictures of the joint gaps on the four sides of the joint between the first component and the second component, and obtain the gap size data of each side. Then, the welding robot will be used to plan and weld the welding sequence of the first component and the second component.

[0023] In summary, this application includes at least one of the following beneficial technical effects: (1) By setting up a ring-shaped baffle mechanism at the four corners of the inner wall of the frame, the wheel body rolls and fits against the edge of the second component, converting sliding friction into rolling friction to reduce the sliding resistance of the component. The micro-motion sensor collects the edge position data of the component in real time, and the control system adjusts the wheel body spacing through closed-loop linkage of the bidirectional cylinder, compensating for wheel body wear play in real time and correcting the component sliding posture. This achieves the goal of ensuring the vertical posture of the second component during vertical sliding throughout the process, avoiding the problems of docking reference offset and uneven docking gap, and improving the docking accuracy of the component and the consistency of welding operation.

[0024] (2) By setting up a two-dimensional comprehensive detection system consisting of a surround industrial camera and a micro-motion sensor, the radial displacement data of the wheel body during the component sliding process and the weld gap size data after docking are collected simultaneously. The system analyzes and distinguishes the component's own deformation, wheel wear, and occasional installation deviation problems, and matches corresponding differentiated treatment solutions to avoid the problem of incorrect adjustment of equipment parameters. This achieves closed-loop treatment of docking deviations, reduces the occurrence of incomplete penetration, weld penetration, porosity, or off-center welding during welding, and ensures that the form and position tolerances of the component after welding meet the subsequent assembly requirements, thereby improving the automation level and operational stability of mass production operations.

[0025] (3) The lifting cylinder drives the top plate carrying the welded component to move vertically downward, so that the second component is completely pulled out from the inside of the frame. Then, the transfer cylinder drives the slide table to slide linearly along the guide rail, and the welded component is moved out of the welding station below the frame as a whole. The unloading of the welded component and the loading of the new component can be quickly completed without disassembling the guide frame, simplifying the loading and unloading operation process and reducing the scraping and collision between the component and the frame during the unloading process. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the welding device for component connections according to the present invention.

[0027] Figure 2 for Figure 1 A partial structural diagram.

[0028] Figure 3 This is a schematic diagram of the mating structure of the positioning component and the catheter component in this invention.

[0029] Figure 4 for Figure 3 A partial structural diagram from another perspective.

[0030] Figure 5 for Figure 4 A schematic diagram of the structure viewed from below.

[0031] Figure 6 This is a partial structural diagram of the catheter assembly in this invention.

[0032] Figure 7This is a top view schematic diagram of the frame, the tube-blocking mechanism, and the workpiece in this invention.

[0033] Figure 8 This is a schematic diagram of the baffle mechanism in this invention.

[0034] Figure 9 for Figure 8 Another perspective structural diagram.

[0035] Figure 10 This is a schematic diagram of the workpiece structure in this invention.

[0036] Explanation of reference numerals in the attached diagram: 1. Workbench; 2. Welding robot; 3. Positioning component; 31. Base; 32. Guide rail; 33. Transfer cylinder; 34. Slide table; 35. Limiting mechanism; 351. Lifting cylinder; 352. Clamping cylinder; 353. Top plate; 354. Clamping block; 355. Push-clamping cylinder; 356. Clamping plate; 357. Pressing cylinder; 358. Column; 4. Grating; 5. Conduit assembly; 51. Upright frame; 52. Horizontal frame; 53. Frame; 54. Pipe-blocking mechanism; 541. Support plate; 542. Bracket; 543. Wheel body; 544. Conical part; 545. Protective cover; 546. Two-way cylinder; 547. Micro-motion sensor; 6. First industrial camera; 7. Second industrial camera; 8. First component; 9. Second component; 10. Copying part; 101. Positioning post. Detailed Implementation

[0037] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0038] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0039] Example 1, please refer to Figures 1-10 The present invention provides the following technical solution: a welding device for component connection, including a workbench 1, a welding robot 2 installed on the top of the workbench 1, the welding robot 2 being used for welding components.

[0040] A positioning component 3 is installed on the top of the workbench 1. The positioning component 3 is used to align and position the first component 8 and the second component 9, so that the welding robot 2 can weld the joint of the components. The specific structure of the positioning component 3 is as follows: The positioning assembly 3 includes a base 31 mounted on the top of the workbench 1. A guide rail 32 is mounted on the top of the base 31. A slide table 34 slides on the top of the guide rail 32. A limiting mechanism 35 is mounted on the top of the slide table 34. The limiting mechanism 35 is used to dock with the first component 8. A transfer cylinder 33 is also mounted on the top of the base 31. The piston rod of the transfer cylinder 33 is connected to the limiting mechanism 35.

[0041] The base 31 provides an installation foundation for the positioning component 3. The guide rail 32 and the slide table 34 cooperate to form a linear sliding pair, providing linear guidance for the limiting mechanism 35. The transfer cylinder 33 drives the slide table 34 and the limiting mechanism 35 at the top to slide back and forth along the guide rail 32 through the extension and retraction of the piston rod. The horizontal position of the limiting mechanism 35 can be adjusted to realize the switching of the loading, docking and welding positions of the first component 8. At the same time, it can adapt to the docking position adjustment of components of different specifications.

[0042] The limiting mechanism 35 includes lifting cylinders 351 installed on both sides of the slide table 34. The piston rods of the two lifting cylinders 351 are connected to the top plate 353. Two sets of push-clamp cylinders 355 are symmetrically installed at the bottom of the top plate 353. The two sets of push-clamp cylinders 355 are arranged opposite each other and their piston rods are connected to clamping blocks 354. Two elongated holes corresponding to the clamping blocks 354 are symmetrically opened on the top of the top plate 353. The clamping blocks 354 pass through the corresponding elongated holes and are used to clamp the side walls of the component in two width directions. The top of the top plate 353 is connected to the column 358 and the contour piece 10. There is a gap between the contour piece 10 and the column 358. The center of the top surface of the contour piece 10 is connected to the positioning column 101.

[0043] The top plate 353 provides a reference platform for the first component 8 to bear and position, and also provides an installation base for the clamping and pressing components. The column 358 and the contour piece 10 provide a reference positioning for the first component 8. The gap between the contour piece 10 and the column 358 can be adapted to the end profile of the first component 8. The first component 8 is stuck outside the contour piece 10, and the side wall of the first component 8 is restricted by the column 358. The positioning post 101 passes through the central hole at the bottom of the first component 8. When the first component 8 is positioned, the push-clamp cylinder 355 first drives the clamping block 354 to move and clamp the two sides of the first component 8.

[0044] A clamping cylinder 352 is installed at the bottom of the top plate 353. The piston rod of the clamping cylinder 352 is connected to a clamping plate 356. An elongated hole corresponding to the clamping plate 356 is opened at the top of the top plate 353. The clamping plate 356 extends to the top of the top plate 353 through the corresponding elongated hole and is used to clamp the side walls of the component in two length directions. Two sets of pressing cylinders 357 are installed on one side of the top plate 353. The pressing end of the pressing cylinder 357 is used to press the top of the component.

[0045] Specifically, the clamping cylinder 352 drives the clamping plate 356 to clamp the side of the first component 8 away from the column 358, and finally the pressing cylinder 357 presses the top of the first component 8. At this time, the first component 8 is positioned in all directions, which facilitates the subsequent docking of the second component 9 and the welding robot 2 to weld the docking point of the two components.

[0046] In Example 2, during actual mass production, after the components to be welded undergo processes such as cutting, stamping, and bending, issues such as surface flatness defects, slight deformation of components, and fluctuations in dimensional tolerances inevitably arise. Components with defects cannot achieve complete fit of the docking reference surface, which can easily lead to uneven docking gaps and misalignment of assembly references. This can result in defects during robotic welding. Even if the welding operation is finally completed, the form and position tolerances of the components will exceed the standard due to the previous deformation and docking deviations, which will directly have an adverse impact on the subsequent assembly process of the whole machine, and may even result in the finished product being unable to be assembled.

[0047] A guide tube assembly 5 is installed on the top of the workbench 1. The guide tube assembly 5 is used to vertically guide the second component 9 to ensure the accuracy of the docking between the first component 8 and the second component 9. The specific structure of the guide tube assembly 5 is as follows: The conduit assembly 5 includes a frame 53 disposed above the limiting mechanism 35 and four sets of tube-blocking mechanisms 54. The centerline of the frame 53 overlaps with the axis of the positioning column 101. The conduit assembly 5 also includes a stand 51 installed on the top of the workbench 1 and a crossbar 52 connected to the side wall of the stand 51. The frame 53 is connected to one side of the crossbar 52. The stand 51 and the crossbar 52 provide vertical support for the frame 53, ensuring the relative positional accuracy between the frame 53 and the lower limiting mechanism 35. The frame 53 provides an overall guide space for the second component 9 to pass through. The four sets of tube-blocking mechanisms 54 are installed around the four corners of the inner wall of the frame 53, which can simultaneously guide and limit the four edges of the second component 9, ensuring that the second component 9 always maintains a vertical posture during vertical sliding, and avoiding tilting and eccentricity.

[0048] The specific structure of the tube-blocking mechanism 54 is as follows: Four sets of tube-stopping mechanisms 54 are equidistantly installed around the four corners of the inner wall of the frame 53. Each set of tube-stopping mechanisms 54 includes a support plate 541 connected to the frame 53 and two wheels 543. A micro-motion sensor 547 is installed on the top of the support plate 541 and between the two wheels 543. The micro-motion sensor 547 can be of the model GEFRAN / PY-2-C-010-XL0202. The two wheels 543 correspond to the two sides of one edge of the second component 9, respectively. That is, the two wheels 543 cooperate to limit the corresponding edge, causing the second component 9 to slide along the limiting guide of the two wheels 543. During the sliding process, the micro-motion sensor 547 can detect the position change of the edge of the second component 9 in real time, capture the attitude deviation of the second component 9 and the change in the fit of the wheels 543, and provide data basis for subsequent attitude correction.

[0049] A protective cover 545 is installed on the top of the support plate 541. The micro-motion sensor 547 is installed inside the protective cover 545. The protective cover 545 can isolate the micro-motion sensor 547 from the external environment, preventing spatter, fumes and debris generated during the welding process from entering the sensor and causing damage to the sensor or a decrease in detection accuracy, thus extending the service life of the sensor.

[0050] The top of the support plate 541 has two sliding supports 542, and two wheels 543 are correspondingly arranged with the two supports 542. The wheels 543 rotate on the side wall of the corresponding support 542. The top of the support plate 541 is equipped with a two-way cylinder 546. The two piston rods of the two-way cylinder 546 are connected to the two supports 542. A tapered part 544 is opened on the opposite side of the two wheels 543.

[0051] The bracket 542 can slide along the top of the support plate 541 to provide a rotating mounting position for the wheel 543; the two-way cylinder 546 can synchronously drive the two brackets 542 to slide towards or away from each other, thereby adjusting the distance between the two wheels 543, which can be adapted to the second component 9 of different specifications. At the same time, the distance can be adjusted when the wheel 543 is worn to compensate for the amount of wear; the tapered part 544 on the wheel 543 can be adapted and fitted to the edge of the second component 9 to increase the contact area between the wheel 543 and the second component 9 and improve the guiding stability.

[0052] Specifically, the tube-blocking mechanism 54 arranged around the four corners of the frame 53, and the wheel 543 with tapered part 544 rolling and adhering to the four edges of the second component 9, convert sliding friction into rolling friction to reduce sliding resistance. The horizontal displacement of the second component 9 is constrained by the synchronous limiting of the four sets of wheels 543, ensuring the vertical posture of the sliding process.

[0053] The micro-motion sensor 547 collects the position data of the edge of the second component 9 in real time, and simultaneously captures the changes in the fit of the wheel body 543 and the guide play. The control system forms a closed loop linkage, drives the bidirectional cylinder 546 to extend and retract to adjust the distance between the wheel body 543, compensates for the play caused by the wear of the wheel body 543 in real time, corrects the posture deviation of the second component 9, avoids the problems of docking reference offset and uneven gap, and improves the docking accuracy of the two components and the consistency of welding operations.

[0054] In addition, during material discharge, the lifting cylinder 351 drives the top plate 353 to move down, causing the second component 9 to be pulled out from the frame 53. Then, the piston rod of the transfer cylinder 33 retracts, causing the slide table 34 to move out from under the frame 53. The welded component is also moved out at the same time. The workers only need to remove the component, reposition the new first component 8, and move the first component 8 back to the bottom of the frame 53. Then, the second component 9 can be inserted into the frame 53.

[0055] The top of the workbench 1 is also equipped with a grating 4. When the welding robot 2 is welding, the grating 4 is used for barrier detection to prevent the worker's hand from going deep into the work position and causing danger.

[0056] In the third embodiment, the second component 9 is guided and limited by only four sets of tube-blocking mechanisms 54. The detection and judgment dimensions are singular, and it is impossible to distinguish between two types of problems: docking deviation caused by the deformation of the second component 9 itself and guiding deviation caused by the wear of the wheel body 543.

[0057] The wear problem of wheel 543 specifically involves the synchronous wear of all four wheels 543, resulting in a continuous overall problem where the deviation increases with the duration of use. The docking deviation problem caused by the deformation of the second component 9 itself can be divided into overall deformation of the second component 9, a sudden change on one side, or unevenness only on the bottom surface of the second component 9. The handling methods for the two types of problems are different. If they cannot be distinguished, the spacing between the wheels 543 may be incorrectly adjusted, and the docking deviation may not be addressed in a targeted manner.

[0058] Therefore, two sets of first industrial cameras 6 and two sets of second industrial cameras 7 are symmetrically installed on the top of the top plate 353. The two sets of first industrial cameras 6 and two sets of second industrial cameras 7 are arranged around the components and are used to photograph the gap between the two components. Specifically, the two sets of first industrial cameras 6 and two sets of second industrial cameras 7 are arranged around the top of the top plate 353.

[0059] A controller is provided that is electrically connected to the micro-motion sensor 547, the first industrial camera 6, and the second industrial camera 7. The controller has a built-in control system, which is configured to perform the following data acquisition and judgment logic.

[0060] Data collection: First, wheel body data acquisition: When the second component 9 slides along the frame 53, the radial displacement of all wheels 543 in the 4 sets of tube-blocking mechanisms 54 is acquired, and the average displacement of all wheels 543 and the maximum displacement difference between all wheels 543 are calculated.

[0061] Second, gap data acquisition: Before the second component 9 and the first component 8 are connected and welded, the gap size of the four welding surfaces is acquired by two sets of first industrial cameras 6 and two sets of second industrial cameras 7, and the average gap of the four surfaces and the maximum gap difference between the four surfaces are calculated.

[0062] Deviation type determination logic: Step 1: First determine whether it is component deformation. If any of the following conditions are met, the gap deviation is directly determined to be caused by the deformation of the second component 9 itself: Condition 1: The maximum displacement difference of all wheel bodies 543 is ≥0.15mm.

[0063] Condition 2: The maximum gap difference between the four surfaces is ≥0.2mm.

[0064] Condition 3: If the test data of this component is abnormal, the test data of the next qualified component of the same specification will fall back to the preset qualified threshold range.

[0065] Corresponding action: Without adjusting the wheel spacing 543, the control system first sorts the welding priority of the four mating surfaces according to the gap size from small to large, and then controls the welding robot 2 to perform graded welding according to the sorting.

[0066] Step 2: Determine if the gap deviation is caused by wheel wear. Only if all three of the following conditions are met can the gap deviation be determined to be caused by wear of wheel body 543: Condition 1: The maximum displacement difference of all wheel bodies 543 is ≤0.03mm.

[0067] Condition 2: The maximum gap difference between the four surfaces is ≤0.05mm.

[0068] Condition 3: The average displacement and average gap of three consecutive batches of qualified square tubes show a continuous increasing trend.

[0069] Corresponding action: Adjust the distance between wheel 543 using the bidirectional cylinder 546 to compensate for wear and update the normal reference value of the equipment. No parts need to be replaced. When the bidirectional cylinder 546 is adjusted to its limit, it indicates that the wear of wheel 543 is too large. The operator only needs to disassemble and replace wheel 543.

[0070] Example 4: A welding method for component joints, using the aforementioned welding apparatus for component joints, includes the following steps: S1. Place the first component 8 on top of the limiting mechanism 35, and use the limiting mechanism 35 to position and lock the first component 8.

[0071] The more specific steps in S1 are as follows: S11. Place the first component 8 on top of the top plate 353, with the side wall of the first component 8 in contact with the outer wall of the column 358. Then, the clamping block 354 is moved by the push-clamping cylinder 355 to clamp the two sides of the first component 8. The clamping plate 356 is then moved by the clamping cylinder 352 to clamp the side of the first component 8 away from the column 358. Finally, the top of the first component 8 is pressed by the pressing cylinder 357. At this time, the first component 8 is positioned in all directions.

[0072] S12. Then, the second component 9 is passed through the interior of the frame 53, so that the bottom end of the second component 9 is attached to the top of the first component 8.

[0073] S2. When the second component 9 is installed, four sets of tube-blocking mechanisms 54 are used to assist in guiding the four edges of the second component 9. That is, two wheels 543 in each set of tube-blocking mechanisms 54 are in contact with the side wall of the second component 9, and the side wall of the second component 9 slides on the corresponding wheel 543 to ensure that the second component 9 remains vertical during the downward sliding process.

[0074] S3. During the entire process of the second component 9 sliding through the tube, the position data of the four edges of the second component 9 are detected in real time by the micro-motion sensors 547 in the four sets of tube-blocking mechanisms 54, and the vertical attitude deviation of the second component 9 and the fitting degree between the corresponding wheel body 543 and the side wall of the second component 9 are judged simultaneously.

[0075] The specific implementation steps of S3 are as follows: S31. If the detection data of the micro-motion sensor 547 shows abnormal fluctuations, it is determined that the vertical posture of the second component 9 is deviated. The corresponding wheel 543 of the baffle mechanism 54 has guide play due to wear, which causes the second component 9 to wobble horizontally when sliding.

[0076] S32. The control system drives the bidirectional cylinder 546 in the corresponding baffle mechanism 54 to contract according to the micro-motion sensor 547 corresponding to the abnormal data, which drives the two supports 542 and wheel 543 of the same baffle mechanism 54 to move closer to each other, reduce the distance between the two wheel 543, and make the conical part 544 of the wheel 543 fit tightly against the side wall of the second component 9 again, eliminate guide play, and correct the vertical posture of the second component 9.

[0077] S4. After the second component 9 is in place, two sets of first industrial cameras 6 and two sets of second industrial cameras 7 are arranged around it to take pictures of the joint gaps on the four sides of the joint between the first component 8 and the second component 9, and obtain the gap size data of each side. Then, the welding robot 2 is used to plan and weld the welding sequence of the first component 8 and the second component 9.

[0078] S41. If the gap size of all four surfaces is within the preset qualified threshold range, the control system controls the welding robot 2 to continuously weld the four butt joints in the preset circumferential welding sequence to complete the component connection.

[0079] S42. If the gap size of at least one surface exceeds the preset acceptable threshold range, it is determined that there is a flatness deviation on the mating surface. The control system first sorts the welding priority of the four mating surfaces in order of gap size from smallest to largest, and then controls the welding robot 2 to perform graded welding according to the sorting: First, perform a root pass welding on the mating surface with the smallest gap size. After that, perform root pass welding on the remaining small gap surfaces in sequence to lock the relative position of the two mating components and limit the amount of deformation in the subsequent welding process.

[0080] Secondly, for large gaps with out-of-tolerance dimensions, a multi-layer welding process is used to complete the welding. First, the root pass is welded to ensure penetration, and then multiple layers of filler welds are used to compensate for gap deviations and complete the welding. Welding shrinkage deformation is used to further correct the butt joint deviations, ensuring the quality of the weld and the strength of the component connection.

[0081] To differentiate the causes of docking deviations and implement closed-loop solutions, this method, in addition to completing the aforementioned attitude correction and welding operations, also incorporates wheel displacement data and gap data for comprehensive judgment and targeted processing, as detailed below: First, following the data acquisition logic of Example 3, the wheel displacement data and butt joint gap data during this welding process are acquired simultaneously, and the corresponding characteristic values ​​are calculated.

[0082] Second, according to the deviation type determination logic of Example 3, the component deformation determination is first performed. If it is determined that the second component 9 itself is deformed, the wheel body 543 parameters are not adjusted, only the welding process is adaptively adjusted, and the component is marked and diverted after welding is completed.

[0083] Third, if the component deformation judgment is not triggered, the wear judgment of wheel body 543 continues. If the wear of wheel body 543 is determined, the bidirectional cylinder 546 is automatically controlled to adjust the stroke to compensate for the wear of wheel body 543, and then the equipment reference parameters are updated synchronously.

[0084] Fourth, if neither the component deformation judgment condition nor the wheel wear judgment condition 543 is met, it is judged as an occasional installation deviation. The control system will issue a prompt, and the operator will manually review and handle the issue.

[0085] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. A welding device for component joints, characterized in that: Including the workbench (1); A welding robot (2) is mounted on top of a workbench (1) and is used for welding components; A positioning component (3) is installed on the top of the workbench (1). The positioning component (3) includes a limiting mechanism (35) that slides on the top of the workbench (1). The limiting mechanism (35) is used to dock with the first component (8). The conduit assembly (5) is installed on the top of the workbench (1) and is used to vertically guide the second component (9). The conduit assembly (5) includes a frame (53) disposed above the limiting mechanism (35) and four sets of tube-blocking mechanisms (54). The four sets of tube-blocking mechanisms (54) are installed equidistantly around the four corners of the inner wall of the frame (53). Each set of tube-blocking mechanisms (54) includes a support plate (541) connected to the frame (53) and two wheels (543). A micro-motion sensor (547) is installed on the top of the support plate (541) and between the two wheels (543). Two sets of first industrial cameras (6) and two sets of second industrial cameras (7) are symmetrically installed on the top of the limiting mechanism (35). The two sets of first industrial cameras (6) and two sets of second industrial cameras (7) are equidistantly arranged around the component and are used to photograph the gap between the two components. The top of the support plate (541) has two brackets (542) that slide on it. Two wheels (543) are correspondingly arranged with the two brackets (542). The wheels (543) rotate on the side wall of the corresponding bracket (542). A two-way cylinder (546) is installed on the top of the support plate (541). The two piston rods of the two-way cylinder (546) are connected to the two brackets (542). A tapered part (544) is opened on the opposite side of the two wheels (543). A protective cover (545) is installed on the top of the support plate (541), and the micro-motion sensor (547) is installed inside the protective cover (545); The workbench (1) is equipped with a base (31) on top, a guide rail (32) is installed on top of the base (31), a slide (34) slides on top of the guide rail (32), the slide (34) slides on top of the guide rail (32), the limiting mechanism (35) is installed on top of the slide (34), and a transfer cylinder (33) is also installed on top of the base (31), the piston rod of the transfer cylinder (33) is connected to the limiting mechanism (35).

2. The welding device for component connections according to claim 1, characterized in that: The conduit assembly (5) also includes a stand (51) mounted on the top of the workbench (1) and a crossbeam (52) connected to the side wall of the stand (51), with the frame (53) connected to one side of the crossbeam (52).

3. The welding device for component connections according to claim 1, characterized in that: The limiting mechanism (35) includes lifting cylinders (351) installed on both sides of the slide (34). The piston rods of the two lifting cylinders (351) are connected to the top plate (353). The two sets of first industrial cameras (6) and two sets of second industrial cameras (7) are all arranged around the top of the top plate (353).

4. A welding device for component connections according to claim 3, characterized in that: Two sets of push-clamp cylinders (355) are symmetrically installed at the bottom of the top plate (353). The two sets of push-clamp cylinders (355) are arranged opposite each other and their piston rods are connected to clamping blocks (354). Two elongated holes corresponding to clamping blocks (354) are symmetrically opened at the top of the top plate (353). The clamping blocks (354) pass through the corresponding elongated holes and are used to clamp the side walls of the component in two width directions. A column (358) and a contour piece (10) are connected to the top of the top plate (353). A gap is provided between the contour piece (10) and the column (358). A positioning column (101) is connected to the middle of the top surface of the contour piece (10). The center line of the frame (53) overlaps with the axis of the positioning column (101).

5. A welding device for component connections according to claim 4, characterized in that: A clamping cylinder (352) is installed at the bottom of the top plate (353). The piston rod of the clamping cylinder (352) is connected to a clamping plate (356). An elongated hole corresponding to the clamping plate (356) is opened at the top of the top plate (353). The clamping plate (356) extends to the top of the top plate (353) through the corresponding elongated hole and is used to clamp the side walls of the component in two length directions.

6. A welding device for component connections according to claim 5, characterized in that: Two sets of clamping cylinders (357) are installed on one side of the top plate (353), and the clamping end of the clamping cylinder (357) is used to clamp the top of the component.

7. A welding method for component joints, using a welding apparatus for component joints as described in claim 6, characterized in that, Includes the following steps: S1. Place the first component (8) on top of the limiting mechanism (35) and lock the first component (8) by the limiting mechanism (35); S2. When the second component (9) is installed, four sets of tube-blocking mechanisms (54) are used to guide the four edges of the second component (9). That is, the two wheels (543) in each set of tube-blocking mechanisms (54) are in contact with the side wall of the second component (9), and the side wall of the second component (9) slides on the corresponding wheel (543) to ensure that the second component (9) remains vertical during the downward sliding process. S3. During the entire process of the sliding of the second component (9), the position data of the four edges of the second component (9) are detected in real time by the micro-motion sensors (547) in the four sets of baffle mechanisms (54), and the vertical attitude deviation of the second component (9) and the fitting degree between the corresponding wheel body (543) and the side wall of the second component (9) are judged simultaneously. S4. After the second component (9) is in place, the first industrial camera (6) and the second industrial camera (7) arranged around it are used to take pictures of the joint gaps on the four sides of the joint between the first component (8) and the second component (9) to obtain the gap size data of each side. Then, the welding robot (2) is used to plan and weld the welding sequence of the first component (8) and the second component (9).

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