Automatic welding equipment for bus handrail flange and end head seal head

Abstract

The application discloses a kind of bus handrail flange and end head automatic welding equipment, it is related to welding technical field, including storage mechanism, the storage mechanism includes support frame and control terminal;It further includes: feeding mechanism, the feeding mechanism fixed mounting is in the top of support frame inner cavity, including handrail pipe feeding mechanism and end head and connecting flange feeding mechanism.The application is accurately controlled by adopting automatic welding system molten pool temperature, wire feeding speed and welding torch moving track, completely eliminate the influence brought by the experience difference and state fluctuation of operator, and weld width is uniform, and it is uniformly, appearance is beautiful, effectively avoid biting edge, pore, slag inclusion and other appearance and internal defects, after welding, it is not necessary to carry out manual polishing treatment, directly shorten production cycle, while reducing material loss and additional labor cost in polishing process, realize handrail pipe, flange and end head automatic feeding, accurate transfer, coaxial butt joint and continuous welding full-process automation.

Description

Technical Field

[0001] This invention relates to the field of welding technology, specifically to an automatic welding equipment for bus handrail flanges and end caps. Background Technology

[0002] Bus handrails are core safety components that ensure the safe operation of urban public transportation and provide stable support and protection for standing passengers. Their structural strength and connection reliability are directly related to passenger safety. In the handrail production process, the connection between the handrail tube, the bottom connecting flange, and the end spherical end cap is a key process that determines the overall structural strength. Due to the limitations of the overall vehicle layout and structural design, except for aluminum alloy handrails, most steel handrails in the industry use welding to achieve a rigid connection of the three components. Moreover, the standard requires double-sided welding, with one side filled with wire and the other side not filled with wire, to ensure the mechanical properties and sealing of the weld.

[0003] In existing technologies, the above-mentioned welding process is generally completed by manual tungsten inert gas welding combined with manual wire feeding. However, this welding method has poor weld quality stability. Since the molten pool temperature, wire feeding speed, and welding torch movement trajectory of manual welding are entirely dependent on the operator's experience and skill level, the welding effect of different workers, or even the same worker under different conditions, varies significantly. It is very easy to produce appearance and internal defects such as uneven weld width, undercut, porosity, and slag inclusion. In order to meet the product appearance requirements, a manual grinding process must be added after welding, which not only prolongs the production cycle but also increases material consumption and labor costs. Therefore, an automatic welding equipment for bus handrail flanges and end caps is proposed. Summary of the Invention

[0004] This invention provides an automatic welding device for bus handrail flanges and end caps to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: An automatic welding device for bus handrail flanges and end caps includes a storage mechanism comprising a support frame and a control terminal; it also includes a feeding mechanism fixedly installed on the top of the inner cavity of the support frame, comprising a handrail tube feeding mechanism and an end cap and connecting flange feeding mechanism. The handrail tube feeding mechanism includes a first six-axis robotic arm fixedly installed on the top of the inner cavity of the processing chamber and a first pneumatic clamping assembly fixedly installed at the end of the first six-axis robotic arm. The output end of the first pneumatic clamping assembly is fixedly connected to a handrail tube clamping head. The end cap and connecting flange feeding mechanism includes a second six-axis robotic arm. The end of the second six-axis robotic arm is fixedly connected to a second pneumatic clamping assembly. The output end of the second pneumatic clamping assembly is fixedly connected to a flange clamping plate. The surface of the flange clamping plate is provided with a spherical end cap adaptation groove. The structure of the second pneumatic clamping assembly is the same as that of the first pneumatic clamping assembly. The transfer and splicing mechanism is fixedly installed in the inner cavity of the support frame and located below the feeding mechanism. It includes a handrail tube transfer mechanism and a head and connecting flange transfer mechanism. The handrail tube transfer mechanism includes a transverse feeding component and a longitudinal feeding component. The transverse feeding component is fixedly installed on the inner wall of the support frame, and the longitudinal feeding component is fixedly installed on top of the transverse feeding component. The head and connecting flange transfer mechanism includes a rotation and feeding component, which is fixedly installed on the inner wall of the support frame. The output end of the rotation and feeding component is fixedly connected to a [missing information].

[0006] A further improvement of the technical solution of the present invention is that: the control terminal is fixedly installed on the surface of the support frame, the upper end of the inner cavity of the support frame is set as a processing cavity, the front and rear sides of the processing cavity are rotatably connected to protective doors by hinges, and the bottom of the inner cavity of the processing cavity is respectively placed with a handrail tube tray, a head and connecting flange tray and a finished product tray.

[0007] A further improvement of the technical solution of the present invention is that: the first pneumatic clamping assembly includes an air inlet, the top of which is fixedly connected to the end of the first six-axis robotic arm, and air chambers are provided inside both sides of the air inlet. A pneumatic system is externally connected to one side of the air chamber, and a piston is slidably connected to the end of the air chamber. A telescopic rod is fixedly connected to one side of the piston, and a mounting bracket is fixedly connected to the end of the telescopic rod. The end of the mounting bracket is fixedly connected to one side of the handrail tube clamping head.

[0008] A further improvement of the technical solution of the present invention is that: the transverse feeding component includes a first guide rail, the bottom of the first guide rail is fixedly connected to the bottom of the inner cavity of the processing cavity, a first slider is slidably connected to the surface of the first guide rail, a first lead screw is threadedly connected to the inside of the first slider, a first motor is fixedly connected to the end of the first lead screw, and the first motor is fixedly installed at the bottom of the inner cavity of the processing cavity.

[0009] A further improvement of the technical solution of the present invention is that: the longitudinal feeding component includes a second guide rail, a second slider is slidably connected to the surface of the second guide rail, a second lead screw is threadedly connected to the inside of the second slider, a second motor is provided at the end of the second lead screw, a handrail tube clamp is fixedly connected to the top of the second slider, a flipping wheel is rotatably connected inside the handrail tube clamp via a rotating shaft, and a flipping motor is provided at the end of the rotating shaft.

[0010] A further improvement of the technical solution of the present invention is that: the rotation and feed assembly includes a third slide rail, the third slide rail is fixedly installed at the bottom of the inner cavity of the processing chamber, a third slider is slidably connected to the surface of the third slide rail, a third lead screw is threadedly connected to the inside of the third slider, a third motor is fixedly connected to the end of the third lead screw, a synchronous motor is fixedly connected to one side of the upper end of the third slider, and a flipping frame is fixedly connected to the output end of the synchronous motor.

[0011] A further improvement of the technical solution of the present invention is that: the clamping assembly includes a first air supply chamber and a second air supply chamber, each of which is divided into two sections and respectively disposed inside the third slider and the flipping frame. The first and second air supply chambers inside the flipping frame are annular and extend to their ends. The first and second air supply chambers inside the third slider are both externally connected to a pneumatic system. The ends of the first and second air supply chambers are slidably connected to piston rods. The ends of the piston rods are fixedly connected to concave clamping heads, and the inner walls of the concave clamping heads are overlapped with welded parts.

[0012] A further improvement to the technical solution of this invention is that it also includes a wire filling and welding mechanism. This mechanism guides the welding wire to the outer splice seam and performs welding. The wire filling and welding mechanism includes a third six-axis robotic arm. The upper end of the third six-axis robotic arm is fixedly connected to the top of the processing cavity. A tungsten inert gas (TIG) welding machine is fixedly connected to the end of the third six-axis robotic arm. An argon gas nozzle and a tungsten electrode are provided at the lower end of the TIG welding machine. A mounting plate is fixedly installed on the surface of the TIG welding machine. A mounting shaft is fixedly connected to one side of the mounting plate. A welding wire coil is rotatably connected to the surface of the mounting shaft. The end of the mounting shaft is threaded with an installation knob. A wire feeding motor is fixedly connected to one side of the mounting plate. A wire feeding roller is fixedly connected to the end of the shaft of the wire feeding motor. A groove is formed on the surface of the mounting plate. A sliding block is slidably connected to the inner wall of the groove. A spring is fixedly connected to one end of the sliding block. The other end of the spring is fixedly connected to one end of the inner cavity of the groove. A clamping roller is rotatably connected to one side of the sliding block. The wire filling and welding mechanism also includes a welding wire guide tube and a visual guidance camera. The welding wire guide tube is fixedly connected to the surface of the tungsten inert gas welding machine through a fixing component. Three sets of visual guidance cameras are provided.

[0013] A further improvement of the technical solution of this invention lies in the following: the control terminal integrates a PLC main controller, a machine vision processing module, a multi-axis servo drive module, a pneumatic solenoid valve control module, a welding process parameter adjustment module, an industrial touch screen human-machine interaction module, and a fault diagnosis and data storage module; the PLC main controller communicates with the controllers of the first, second, and third six-axis robotic arms via an EtherCAT industrial bus, and is connected via hardwire to the drivers of the first, second, and third motors, the tilting motor, the synchronous motor, and the wire feed motor, the pneumatic system solenoid valve group, and the control interface of the tungsten inert gas welding machine; the machine vision processing module is connected to three sets of vision guidance cameras via gigabit Ethernet, used to extract workpiece contour features, calculate spatial coordinates, detect the butt joint gap width and coaxiality, and transmit positioning deviation and welding path compensation data to the PLC main controller in real time; the multi-axis servo drive module is integrated inside the PLC main controller. The differential pulse signal output precisely controls the speed, displacement, and start / stop sequence of each servo motor; the pneumatic solenoid valve control module adjusts the clamping pressure and action speed of the first pneumatic clamping assembly, the second pneumatic clamping assembly, the first air supply chamber, and the second air supply chamber by controlling the on / off state and air pressure of different air paths; the welding process parameter control module collects the output current, voltage, wire feed speed, and argon flow signals of the tungsten inert gas welding machine in real time, compares them with the preset process curve, and performs closed-loop adjustment; the industrial touch screen human-machine interaction module is used to input welding process parameters of different specifications of handrails, switch between automatic and manual operation modes, and display the real-time operating status and production statistics of the equipment; the fault diagnosis and data storage module monitors the operating signals of each sensor and actuator in real time. When the workpiece positioning deviation exceeds the limit, the welding current is abnormal, the pneumatic pressure is insufficient, or the motor is overloaded, it immediately triggers an audible and visual alarm and controls the equipment to stop safely, while automatically recording the fault code, the time of occurrence, and the corresponding welding parameters.

[0014] A further improvement to the technical solution of the present invention is that the full-process collaborative control logic of the control terminal is executed according to the following steps: System initialization: The PLC main controller sends a reset command to control all robotic arms and transfer mechanisms to return to their original positions, the pneumatic system is pressurized to the set pressure, the welding system completes self-test, and at the same time reads the dimensional parameters and corresponding welding process parameters of the handrail tube, end cap and flange to be processed from the industrial touch screen; Automatic feeding: The vision guidance camera at the bottom of the second pneumatic clamping assembly captures images of the end cap and connecting flange tray. The machine vision processing module identifies and calculates the center coordinates and angles of each workpiece. The PLC main controller controls the second six-axis robotic arm to move the second pneumatic clamping assembly to the corresponding position. The pneumatic solenoid valve control module drives the second pneumatic clamping assembly to clamp the workpiece and place it at the end of the flipping frame of the end cap and connecting flange transfer mechanism. The first and second air supply chambers are ventilated to drive the piston rod to extend, which drives the concave clamping head to clamp the workpiece. Subsequently, the vision guidance camera at the bottom of the first pneumatic clamping assembly positions the handrail tube in the handrail tube tray. The PLC main controller controls the first six-axis robotic arm to grab the handrail tube and place it on the handrail tube clamping part of the handrail tube transfer mechanism. Precise docking: The PLC main controller controls the first motor to drive the first slider to move along the first guide rail to the welding station, and controls the third motor to drive the third slider to move along the third guide rail to the corresponding docking position; the vision guidance camera inside the fixing component captures the docking end face of the handrail tube and the end cap or flange, the machine vision processing module calculates the coaxiality deviation and end face gap of the two, the PLC main controller controls the second motor to drive the second slider to make X-axis fine adjustment along the second guide rail, and controls the flipping motor and synchronous motor to drive the handrail tube and the end cap or flange to rotate to the same angle until the docking gap is controlled within the range of 0.2-0.5mm; Closed-loop welding: The PLC main controller controls the third six-axis robotic arm to move the tungsten inert gas (TIG) welding machine to the welding start point. The welding process parameter control module starts the welding machine and outputs the preset arc-starting current. The wire feeding motor feeds the wire at the set speed. During the welding process, the vision guidance camera tracks the position of the weld pool and the gap in real time. The PLC main controller corrects the movement trajectory of the third six-axis robotic arm in real time according to the feedback signal. At the same time, the welding process parameter control module automatically adjusts the welding current and wire feeding speed according to the welding position. After completing the circumferential weld, the arc is automatically extinguished and the argon gas is turned off. Finished product unloading: After welding is completed, the PLC main controller controls the head and connecting flange transfer mechanism to release the workpiece, and controls the handrail tube transfer mechanism to drive the finished product back to the unloading position. The first six-axis robotic arm grabs the finished handrail and places it into the finished product tray. All mechanisms are reset to the origin, ready to enter the next work cycle.

[0015] Due to the adoption of the above technical solution, the technical progress achieved by this invention compared to the prior art is as follows: This invention provides an automatic welding equipment for bus handrail flanges and end caps. By employing an automated welding system to precisely control the molten pool temperature, wire feeding speed, and welding torch movement trajectory, it completely eliminates the influence of operator experience differences and fluctuations in conditions. The welds are uniform in width and aesthetically pleasing, effectively avoiding external and internal defects such as undercut, porosity, and slag inclusions. Post-weld manual grinding is unnecessary, directly shortening the production cycle and reducing material waste and additional labor costs during grinding. The equipment achieves fully automated loading and unloading, precise transfer, coaxial docking, and continuous welding of handrail tubes, flanges, and end caps, significantly reducing the labor intensity of workers. Operators only need to complete batch loading work and do not need to hold professional welding qualifications, significantly reducing personnel training costs and employment barriers, and greatly improving production efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the protective door in the open state of the present invention; Figure 3 This is a schematic diagram of the handrail tube loading and unloading mechanism of the present invention; Figure 4 This is a schematic diagram of the feeding mechanism for the end caps and connecting flanges of the present invention.

[0017] Figure 5 This is a schematic diagram of the end structure of the wire filling and welding mechanism of the present invention; Figure 6 This is a schematic diagram of the handrail tube transfer mechanism of the present invention; Figure 7 This is a schematic diagram of the overall structure of the wire filling and welding mechanism of the present invention; Figure 8 This is a schematic diagram of the structure of the head and connecting flange transfer mechanism of the present invention.

[0018] Figure 9 This is a cross-sectional structural schematic diagram of the head and connecting flange transfer mechanism of the present invention; Figure 10 This is a cross-sectional view of the handrail tube loading and unloading mechanism of the present invention. Figure 11 For the present invention Figure 6 Enlarged structural diagram at point A in the middle; Figure 12 For the present invention Figure 7 Enlarged structural diagram at point B.

[0019] In the diagram: 11. Support frame; 12. Processing chamber; 13. Protective door; 14. Control terminal; 15. Handrail tube tray; 16. End cap and connecting flange tray; 17. Finished product tray; 21. First six-axis robotic arm; 22. First pneumatic clamping assembly; 23. Handrail tube clamping head; 221. Air inlet; 222. Air chamber; 223. Piston; 224. Telescopic rod; 225. Mounting bracket; 31. Second six-axis robotic arm; 32. Second pneumatic clamping assembly; 33. Flange clamping plate; 34. Spherical end cap adaptation groove; 41. First guide rail; 42. First slider; 43. First lead screw; 44. First motor; 45. Second guide rail; 46. Second slider; 47. Second lead screw ; 48. Second motor; 49. Handrail tube clamp; 410. Tilting wheel; 411. Tilting motor; 51. Third slide rail; 52. Third slider; 53. Third lead screw; 54. Third motor; 55. Synchronous motor; 56. Tilting frame; 57. First air supply chamber; 58. Second air supply chamber; 59. Piston rod; 510. Concave clamping head; 511. Welded part; 61. Third six-axis robotic arm; 62. Tungsten inert gas welding machine; 63. Mounting plate; 64. Mounting shaft; 65. Welding wire coil; 66. Wire feeding motor; 67. Wire feeding roller; 68. Slide groove; 69. Sliding block; 610. Spring; 611. Clamping roller; 612. Welding wire guide tube; 613. Visual guidance camera. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to embodiments: Example 1, as Figures 1-12As shown, the present invention provides an automatic welding equipment for bus handrail flanges and end caps, including a storage mechanism comprising a support frame 11 and a control terminal 14; and a feeding mechanism fixedly installed on the top of the inner cavity of the support frame 11, comprising a handrail tube loading / unloading mechanism and an end cap and connecting flange loading mechanism. The handrail tube loading / unloading mechanism includes a first six-axis robotic arm 21 fixedly installed on the top of the inner cavity of the processing chamber 12 and a first pneumatic clamping assembly 22 fixedly installed at the end of the first six-axis robotic arm. The output end of the first pneumatic clamping assembly 22 is fixedly connected to a handrail tube clamping head 23. The end cap and connecting flange loading mechanism includes a second six-axis robotic arm 31, the end of which is fixedly connected to a second pneumatic clamping assembly 32. The output end is fixedly connected to a flange clamping plate 33, and the surface of the flange clamping plate 33 is provided with a spherical end cap adaptation groove 34. The structure of the second pneumatic clamping assembly 32 is the same as that of the first pneumatic clamping assembly 22. The transfer and splicing mechanism is fixedly installed in the inner cavity of the support frame 11 and located below the feeding mechanism. It includes a handrail tube transfer mechanism and an end cap and connecting flange transfer mechanism. The handrail tube transfer mechanism includes a transverse feeding assembly and a longitudinal feeding assembly. The transverse feeding assembly is fixedly installed on the inner wall of the support frame 11, and the longitudinal feeding assembly is fixedly installed on the top of the transverse feeding assembly. The end cap and connecting flange transfer mechanism includes a rotation and feeding assembly. The rotation and feeding assembly is fixedly installed on the inner wall of the support frame 11, and the output end of the rotation and feeding assembly is fixedly connected to a clamping assembly.

[0021] It should be noted that: the support frame 11 constitutes the main load-bearing structure of the equipment, providing the installation foundation for all functional mechanisms; the control terminal 14 realizes human-machine interaction, used to input welding parameters, monitor equipment operating status, and handle fault alarms; the processing chamber 12 forms a closed welding operation space, isolating welding arc light, fumes, and noise; the protective door 13 serves as a safety protection device to prevent personnel from accidentally touching moving parts and being injured by arc light; the handrail tube tray 15 is used to store handrail tube blanks to be processed in batches; the end cap and connecting flange tray 16 is used to store spherical end caps and connecting flanges to be welded in batches; and the finished product tray 17 is used to centrally store the finished bus handrails that have been welded.

[0022] In this embodiment, by integrating four core functional modules—material storage, loading and unloading, transfer, and welding—an integrated automatic welding equipment architecture is constructed, realizing the foundation for fully automated operation from material storage to finished product output, and changing the traditional manual single-station decentralized welding production mode.

[0023] Example 2, as Figures 1-12As shown, based on Embodiment 1, the present invention provides a technical solution: Preferably, the control terminal 14 is fixedly installed on the surface of the support frame 11. The upper end of the inner cavity of the support frame 11 is set as a processing cavity 12. The front and rear sides of the processing cavity 12 are rotatably connected to protective doors 13 via hinges. The bottom of the inner cavity of the processing cavity 12 is respectively placed with a handrail tube tray 15, a head and connecting flange tray 16, and a finished product tray 17. The first pneumatic clamping assembly 22 includes an air inlet 221. The top of the air inlet 221 is fixedly connected to the end of the first six-axis robotic arm 21. Air chambers 222 are opened inside both sides of the air inlet 221. A pneumatic system is externally connected to one side of the inner cavity of the air chamber 222. A piston 223 is slidably connected to the end of the air chamber 222. A telescopic rod 224 is fixedly connected to one side of the piston 223. A mounting bracket 225 is fixedly connected to the end of the telescopic rod 224. The end of the armrest tube clamp 23 is fixedly connected to one side. The transverse feeding component includes a first guide rail 41. The bottom of the first guide rail 41 is fixedly connected to the bottom of the inner cavity of the processing cavity 12. A first slider 42 is slidably connected to the surface of the first guide rail 41. A first lead screw 43 is threadedly connected to the inside of the first slider 42. A first motor 44 is fixedly connected to the end of the first lead screw 43. The first motor 44 is fixedly installed at the bottom of the inner cavity of the processing cavity 12. The longitudinal feeding component includes a second guide rail 45. A second slider 46 is slidably connected to the surface of the second guide rail 45. A second lead screw 47 is threadedly connected to the inside of the second slider 46. A second motor 48 is provided at the end of the second lead screw 47. An armrest tube clamp 49 is fixedly connected to the top of the second slider 46. A flipping wheel 410 is rotatably connected to the inside of the armrest tube clamp 49 through a rotating shaft. A flipping motor 411 is provided at the end of the rotating shaft.

[0024] It should be noted that: the first six-axis robotic arm 21 provides multi-degree-of-freedom motion capability, driving the first pneumatic clamping assembly to complete the grasping, transfer, and placement of the handrail tube; the first pneumatic clamping assembly 22 realizes the opening and closing action of the handrail tube clamping head through pneumatic power; the handrail tube clamping head 23 is adapted to the outer cylindrical surface of the handrail tube, providing a stable clamping force; the air inlet 221 serves as the interface of the pneumatic system, introducing compressed air into the air chamber; the air chamber 222 provides a sealed pressure space for piston movement; the piston 223 generates linear motion under the action of compressed air; the telescopic rod 224 transmits the piston's motion force to the mounting bracket; the mounting bracket 225 connects the telescopic rod and the handrail tube clamping head to achieve synchronous clamping action; the second six-axis robotic arm 31 provides multi-degree-of-freedom motion, driving the second pneumatic clamping assembly to complete the loading action of the end cap and flange; the second pneumatic clamping assembly 32 realizes the opening and closing action of the flange clamping plate through pneumatic power; the flange clamping plate 33 is used to clamp planar... The connecting flange; the spherical end cap adapts to the groove 34, which fits against the outer surface of the spherical end cap to ensure stable clamping of the end cap without slippage; the first guide rail 41 provides horizontal motion guidance for the first slider; the first slider 42 slides along the first guide rail, driving the second guide rail mechanism above to move as a whole; the first lead screw 43 converts the rotational motion of the first motor into the linear motion of the first slider; the first motor 44 provides precise power output for the movement of the first slider; the second guide rail 45 provides motion guidance for the second slider; the second slider 46 slides along the second guide rail, driving the handrail tube clamping component to move; the second lead screw 47 converts the rotational motion of the second motor into the linear motion of the second slider; the second motor 48 provides precise power output for the movement of the second slider; the handrail tube clamping component 49 is used to support and fix the handrail tube to be welded; the turning wheel 410 contacts the surface of the handrail tube and drives the handrail tube to rotate through friction; the turning motor 411 provides power for the rotation of the turning wheel.

[0025] In this embodiment, two independent six-axis robotic arms, in conjunction with pneumatic clamping components, enable precise gripping and rapid transfer of handrail tubes, end caps, and flanges. The handrail tube transfer mechanism, driven by a dual-guide rail screw, achieves millimeter-level precise positioning of the handrail tubes. The handrail tubes are rotated at a uniform speed by a flipping wheel, meeting the requirements for ring welding of bus handrails.

[0026] Example 3, as Figures 1-12As shown, based on Embodiment 1, the present invention provides a technical solution: Preferably, the rotation and feeding assembly includes a third slide rail 51, which is fixedly installed at the bottom of the inner cavity of the processing chamber 12. A third slider 52 is slidably connected to the surface of the third slide rail 51. A third lead screw 53 is threadedly connected to the inside of the third slider 52. A third motor 54 is fixedly connected to the end of the third lead screw 53. A synchronous motor 55 is fixedly connected to one side of the upper end of the third slider 52. A flipping frame 56 is fixedly connected to the output end of the synchronous motor 55. The clamping assembly includes a first air supply chamber 57 and a second air supply chamber 58. Each air chamber 58 is divided into two sections, respectively located inside the third slider 52 and the flipping frame 56. The first air supply chamber 57 and the second air supply chamber 58 inside the flipping frame 56 are annular, extending to their ends. Both the first air supply chamber 57 and the second air supply chamber 58 inside the third slider 52 are externally connected to a pneumatic system. A piston rod 59 is slidably connected to the ends of both the first air supply chamber 57 and the second air supply chamber 58. A concave clamping head 510 is fixedly connected to the end of the piston rod 59. A welded part 511 overlaps the inner wall of the concave clamping head 510. The system also includes a wire filling and welding mechanism. The feeding mechanism guides the welding wire to the outer splice gap and performs welding. The wire feeding and welding mechanism includes a third six-axis robotic arm 61. The upper end of the third six-axis robotic arm 61 is fixedly connected to the top of the inner cavity of the processing chamber 12. A tungsten inert gas (TIG) welding machine 62 is fixedly connected to the end of the third six-axis robotic arm 61. An argon gas nozzle and a tungsten electrode are provided at the lower end of the TIG welding machine 62. A mounting plate 63 is fixedly mounted on the surface of the TIG welding machine 62. A mounting shaft 64 is fixedly connected to one side of the mounting plate 63. A welding wire coil 65 is rotatably connected to the surface of the mounting shaft 64. A mounting knob is threadedly connected to the end of the mounting shaft 64. A mounting plate 64 is fixedly mounted on one side of the mounting plate 63. A wire feeding motor 66 is fixedly connected, and a wire feeding roller 67 is fixedly connected to the end of the shaft of the wire feeding motor 66. A groove 68 is opened on the surface of the mounting plate 63. A sliding block 69 is slidably connected to the inner wall of the groove 68. A spring 610 is fixedly connected to one end of the sliding block 69, and the other end of the spring 610 is fixedly connected to one end of the inner cavity of the groove 68. A clamping roller 611 is rotatably connected to one side of the sliding block 69. The wire filling and welding mechanism also includes a welding wire guide tube 612 and a vision guidance camera 613. The welding wire guide tube 612 is fixedly connected to the surface of the tungsten inert gas welding machine 62 through a fastener. Three sets of vision guidance cameras 613 are provided.

[0027] It should be noted that: the third slide rail 51 provides horizontal motion guidance for the third slider; the third slider 52 slides along the third slide rail, driving the synchronous motor and the overall movement of the tilting frame; the third lead screw 53 converts the rotational motion of the third motor into the linear motion of the third slider; the third motor 54 provides precise power output for the movement of the third slider; the synchronous motor 55 drives the tilting frame to rotate at a constant speed, realizing the synchronous circumferential rotation of the end cap and flange following the handrail tube; the first air supply chamber 57 provides a compressed air channel for the extension and retraction of one side piston rod; the second air supply chamber 58 provides a compressed air channel for the extension and retraction of the other side piston rod; the piston rod 59 extends or retracts under the action of compressed air, driving the concave clamping head to move; clamping the end cap and flange; the third six-axis robotic arm 61 provides multi-degree-of-freedom motion, driving the welding torch to complete the entire process. Position welding; a tungsten inert gas (TIG) welding machine 62 generates a stable welding arc, melting the base material to form a weld; a mounting plate 63 serves as the mounting base for the wire feeding mechanism; a mounting shaft 64 is used to install and fix the welding wire roll; the welding wire roll 65 stores solid welding wire for welding; a wire feeding motor 66 drives the wire feeding roller to rotate, realizing automatic feeding of the welding wire; the wire feeding roller 67 drives the welding wire forward through friction; a chute 68 provides linear motion guidance for the sliding block; the sliding block 69 slides along the chute, driving the clamping roller to adjust its position; a spring 610 provides preload force, ensuring that the clamping roller always presses the welding wire; the clamping roller 611 cooperates with the wire feeding roller to clamp the welding wire, ensuring stable wire feeding; the welding wire guide tube 612 precisely guides the welding wire to the welding pool position; a vision guidance camera 613 acquires workpiece images, realizing visual positioning of the welding position and real-time tracking of the weld.

[0028] In this embodiment, the clamping mechanism of the annular gas supply chamber enables high-precision clamping and synchronous rotation of the end cap and flange; the tungsten inert gas welding system with integrated automatic wire feeding mechanism enables automatic switching between two welding modes: filler wire and no filler wire; and three sets of distributed vision guidance cameras enable accurate identification and positioning of the workpiece and real-time tracking and correction of the weld, significantly improving welding accuracy and quality consistency.

[0029] Example 4, as Figures 1-12As shown, based on embodiments one to three, the present invention provides a technical solution: Preferably, the control terminal 14 has a built-in PLC main controller, a machine vision processing module, a multi-axis servo drive module, a pneumatic solenoid valve control module, a welding process parameter adjustment module, an industrial touch screen human-machine interaction module, and a fault diagnosis and data storage module; the PLC main controller is connected to the controllers of the first six-axis robotic arm 21, the second six-axis robotic arm 31, and the third six-axis robotic arm 61 via an EtherCAT industrial bus, and is connected via hard wire to the drivers of the first motor 44, the second motor 48, the third motor 54, the tilting motor 411, the synchronous motor 55, the wire feeding motor 66, the pneumatic system solenoid valve group, and the control interface of the tungsten inert gas welding machine 62; the machine vision processing module is connected to three sets of vision guidance cameras 613 via gigabit Ethernet, used to extract workpiece contour features, calculate spatial coordinates, detect the width and coaxiality of the butt joint gap, and transmit the positioning deviation and welding path compensation data to the PLC main controller in real time; the multi-axis servo drive... The module is integrated into the PLC main controller, outputting differential pulse signals to precisely control the speed, displacement, and start / stop sequence of each servo motor; the pneumatic solenoid valve control module adjusts the clamping pressure and action speed of the first pneumatic clamping component 22, the second pneumatic clamping component 32, and the first and second air supply chambers 57 and 58 by controlling the on / off state and air pressure of different air paths; the welding process parameter control module collects the output current, voltage, wire feeding speed, and argon flow signals of the tungsten inert gas welding machine 62 in real time, compares them with the preset process curve, and performs closed-loop adjustment; the industrial touch screen human-machine interaction module is used to input welding process parameters for different specifications of handrails, switch between automatic and manual operation modes, and display the real-time operating status and production statistics of the equipment; the fault diagnosis and data storage module monitors the operating signals of each sensor and actuator in real time. When the workpiece positioning deviation exceeds the limit, the welding current is abnormal, the pneumatic pressure is insufficient, or the motor is overloaded, it immediately triggers an audible and visual alarm and controls the equipment to stop safely, while automatically recording the fault code, occurrence time, and corresponding welding parameters; The full-process collaborative control logic of control terminal 14 is executed according to the following steps: System initialization: The PLC main controller sends a reset command to control all robotic arms and transfer mechanisms to return to their original positions, the pneumatic system is pressurized to the set pressure, the welding system completes self-test, and at the same time reads the dimensional parameters and corresponding welding process parameters of the handrail tube, end cap and flange to be processed from the industrial touch screen; Automatic feeding: The visual guidance camera 613 at the bottom of the second pneumatic clamping assembly 32 captures images of the end cap and connecting flange tray 16. The machine vision processing module identifies and calculates the center coordinates and angles of each workpiece. The PLC main controller controls the second six-axis robotic arm 31 to move the second pneumatic clamping assembly 32 to the corresponding position. The pneumatic solenoid valve control module drives the second pneumatic clamping assembly 32 to clamp the workpiece and place it at the end of the flipping frame 56 of the end cap and connecting flange transfer mechanism. The first air supply chamber 57 and the second air supply chamber 58 are ventilated to drive the piston rod 59 to extend, which drives the concave clamping head 510 to clamp the workpiece. Subsequently, the visual guidance camera 613 at the bottom of the first pneumatic clamping assembly 22 positions the handrail tube in the handrail tube tray 15. The PLC main controller controls the first six-axis robotic arm 21 to grab the handrail tube and place it on the handrail tube clamping part 49 of the handrail tube transfer mechanism. Precise docking: The PLC main controller controls the first motor 44 to drive the first slider 42 to move along the first guide rail 41 to the welding station, and controls the third motor 54 to drive the third slider 52 to move along the third guide rail 51 to the corresponding docking position; the visual guidance camera 613 inside the fixing component captures the docking end face of the handrail tube and the end cap or flange, the machine vision processing module calculates the coaxiality deviation and end face gap of the two, the PLC main controller controls the second motor 48 to drive the second slider 46 to perform X-axis fine adjustment along the second guide rail 45, and controls the flipping motor 411 and the synchronous motor 55 to drive the handrail tube and the end cap or flange to rotate to the same angle until the docking gap is controlled within the range of 0.2-0.5mm; Closed-loop welding: The PLC main controller controls the third six-axis robotic arm 61 to move the tungsten inert gas (TIG) welding machine 62 to the welding starting point. The welding process parameter control module starts the welding machine and outputs the preset arc starting current. The wire feeding motor 66 feeds the wire at the set speed. During the welding process, the vision guidance camera 613 tracks the position of the weld pool and the gap in real time. The PLC main controller corrects the movement trajectory of the third six-axis robotic arm 61 in real time according to the feedback signal. At the same time, the welding process parameter control module automatically adjusts the welding current and wire feeding speed according to the welding position. After completing the 360° circumferential weld, the arc is automatically extinguished and the argon gas is turned off. Finished product unloading: After welding is completed, the PLC main controller controls the head and connecting flange transfer mechanism to release the workpiece, and controls the handrail tube transfer mechanism to drive the finished product back to the unloading position. The first six-axis robotic arm 21 grabs the finished handrail and places it into the finished product tray 17. All mechanisms are reset to the origin, ready to enter the next work cycle.

[0030] In this embodiment, the control terminal 14 realizes centralized control and precise coordinated action of all mechanisms of the equipment. Combined with the real-time visual feedback of three sets of visual guidance cameras 613, a closed-loop control system for the entire process is formed, which completely eliminates the errors caused by manual operation and ensures the stability and consistency of welding quality. At the same time, through the perfect safety interlocking mechanism and fault self-diagnosis function, the safety and reliability of equipment operation are effectively guaranteed, realizing fully automatic and unmanned welding production of bus handrail flanges and end caps.

[0031] The working principle of the automatic welding equipment for the handrail flanges and end caps of this bus will be explained in detail below.

[0032] like Figures 1-12 As shown, after the equipment is powered on, the control terminal 14 first executes a system self-test program to check the communication and operating status of all motors, robotic arms, pneumatic components, and cameras. After the self-test passes, the control terminal 14 sends a command to control all mechanisms to automatically return to the preset origin position. The operator neatly places the handrail tubes, spherical heads, and connecting flanges to be processed on the handrail tube tray 15, the head and connecting flange tray 16, respectively, and closes the protective doors 13 on both sides of the processing chamber 12. Then, the corresponding workpiece model is selected on the touch screen of the control terminal 14, and the system automatically calls the pre-stored welding process parameters, including welding current, welding voltage, wire feed speed, workpiece rotation speed, advance gas supply time, and lag gas stop time. After confirming that the parameters are correct, the start button is pressed, and the equipment enters the automatic operation mode.

[0033] Handrail tube loading process: The control terminal 14 sends a motion command to the first six-axis robotic arm 21, which moves the first pneumatic clamping assembly 22 above the handrail tube tray 15. A vision guidance camera 613 mounted on the bottom of the first pneumatic clamping assembly 22 captures an image of the handrail tube on the tray and transmits the image information to the control terminal 14. The control terminal 14 processes the image, identifies the position and orientation of the handrail tube, and calculates the trajectory of the robotic arm. Then, the control terminal 14 adjusts the orientation of the robotic arm so that the handrail tube clamping head 23 is aligned with the center of the handrail tube. Next, the control terminal 14 controls the solenoid valve of the first pneumatic clamping assembly 22 to actuate, compressing air into the air chamber 222, pushing the piston 223 and the telescopic rod 224 to extend, causing the handrail tube clamping heads 23 on both sides to clamp the handrail tube. The robotic arm moves the clamped handrail tube above the handrail tube transfer mechanism, placing it stably on the handrail tube clamping component 49. The second motor 48 starts, driving the second slider 46 along the second guide rail 45 via the second lead screw 47 to clamp the handrail tube. Then, the pneumatic clamping assembly releases, the robotic arm returns to the standby position, and the control terminal 14 starts the first motor 44 of the handrail tube transfer mechanism, driving the first slider 42 along the first guide rail 41 via the first lead screw 43 to transport the handrail tube to the welding station.

[0034] The loading process for end caps and flanges is carried out simultaneously with the loading of the handrail tube. The control terminal 14 sends a motion command to the second six-axis robotic arm 31, which moves the second pneumatic clamping assembly 32 above the end cap and connecting flange tray 16. The vision guidance camera 613 installed at the bottom of the second pneumatic clamping assembly 32 identifies the position of the spherical end cap and connecting flange, guiding the robotic arm to grab a connecting flange or spherical end cap and transfer it to the right concave clamping head 510 of the end cap and connecting flange transfer mechanism. Then, the control terminal 14 controls the first air supply chamber 57 to supply compressed air, pushing the piston rod 59 to extend and clamp the connecting flange or spherical end cap. The spherical end cap adaptation groove 34 on the surface of the flange clamping plate 33 is completely fitted with the outer surface of the spherical end cap, ensuring stable clamping without slippage. At the same time, the control terminal 14 controls the third motor 54 of the end cap and connecting flange transfer mechanism to start, which drives the third slider 52 to move along the third slide rail 51 through the third lead screw 53, bringing the end cap or flange closer to the end of the handrail tube.

[0035] A vision guidance camera 613 mounted on the side of the welding torch captures real-time images of the mating area, while the control terminal 14 detects the mating gap and coaxiality between the handrail tube and the end cap / flange. If the gap is too large or the coaxiality deviation exceeds the allowable value, the control terminal 14 automatically adjusts the positions of the handrail tube transfer mechanism and the end cap / flange transfer mechanism until the mating gap is controlled between 0.1 and 0.3 mm and the coaxiality deviation is less than 0.05 mm. After the mating is completed, the handrail tube clamp 49 and the concave clamp head 510 remain clamped to prevent workpiece displacement during welding.

[0036] The control terminal 14 sends a motion command to the third six-axis robotic arm 61. The robotic arm moves the tungsten inert gas (TIG) welding machine 62 to the starting position of the outer weld seam, maintaining the distance between the tungsten electrode and the workpiece surface at 2-3 mm. Then, the control terminal 14 controls the TIG welding machine 62 to output argon gas 1 second in advance to purge air from the welding area and prevent weld oxidation. Next, the welding power source ignites the arc, generating a stable welding arc. Simultaneously, the control terminal 14 controls the wire feed motor 66 to start, driving the wire feed roller 67 to rotate, and the welding wire is precisely fed to the weld pool through the welding wire guide tube 612.

[0037] In the wire feeding mechanism, spring 610 pushes sliding block 69 to move along slide groove 68, so that clamping roller 611 always presses the welding wire, ensuring a stable wire feeding speed. Control terminal 14 controls synchronous motor 55 and tilting motor 411 to start simultaneously, driving the end cap or flange and handle tube to rotate synchronously at the same speed. The welding torch remains stationary, and the workpiece rotates one revolution to complete the outer filler wire welding.

[0038] After the outer welding is completed, the control terminal 14 stops the wire feeding motor 66, and the wire feeding mechanism stops feeding wire. After the sixth-axis robotic arm adjusts the position of the tungsten inert gas (TIG) welding machine 62, the workpiece continues to rotate one revolution to complete the inner welding without filler wire. During the welding process, the vision guidance camera 613 tracks the weld position in real time. If a weld deviation is detected, the control terminal 14 automatically adjusts the position of the welding torch to correct it. After welding is completed, the control terminal 14 controls the TIG welding machine 62 to stop outputting argon gas after a 2-second delay to protect the high-temperature weld from oxidation, and then the welding torch returns to the standby position.

[0039] After welding is completed, the control terminal 14 controls the first air supply chamber 57 and the second air supply chamber 58 to exhaust air, the piston rod 59 retracts, and the concave clamping head 510 releases the end cap or flange. Then, the third motor 54 reverses, driving the third slider 52 back to its original position. At the same time, the first motor 44 and the second motor 48 of the handrail tube transfer mechanism reverse, driving the welded finished product back to the unloading position.

[0040] The first six-axis robotic arm 21 restarts, moving the first pneumatic gripping assembly 22 above the finished product. After clamping the product, the second motor 48 reverses, releasing the product. The first six-axis robotic arm 21 then transfers the product to the finished product tray 17 and releases it. If the finished product tray 17 is full, the control terminal 14 will issue an audible and visual alert to remind the operator to replace the tray.

[0041] The equipment automatically repeats the above-mentioned feeding, docking, welding, and unloading processes to achieve continuous automated production. Throughout the production process, the control terminal 14 monitors the operating status of all mechanisms in real time. If insufficient material, workpiece gripping failure, welding abnormality, or other malfunctions are detected, the equipment immediately stops operating, the control terminal 14 displays the fault code and cause of the fault, and issues an audible and visual alarm. After the operator troubleshoots the fault, pressing the reset button allows the equipment to resume operation from the point of interruption.

[0042] The present invention has been described in detail above. However, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, any modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention.

Claims

1. An automatic welding device for bus handrail flanges and end caps, comprising a material storage mechanism, wherein the material storage mechanism includes a support frame (11) and a control terminal (14); characterized in that: Also includes: The feeding mechanism is fixedly installed on the top of the inner cavity of the support frame (11), including a handrail tube feeding mechanism and a head and connecting flange feeding mechanism. The handrail tube feeding mechanism includes a first six-axis robotic arm (21) fixedly installed on the top of the inner cavity of the processing cavity (12) and a first pneumatic clamping assembly (22) fixedly installed at the end of the first six-axis robotic arm. The output end of the first pneumatic clamping assembly (22) is fixedly connected to a handrail tube clamping head (23). The head and connecting flange feeding mechanism includes a second six-axis robotic arm (31). The end of the second six-axis robotic arm (31) is fixedly connected to a second pneumatic clamping assembly (32). The output end of the second pneumatic clamping assembly (32) is fixedly connected to a flange clamping plate (33). The surface of the flange clamping plate (33) is provided with a spherical head adaptation groove (34). The structure of the second pneumatic clamping assembly (32) is the same as that of the first pneumatic clamping assembly (22). The transfer and splicing mechanism is fixedly installed in the inner cavity of the support frame (11) and located below the feeding mechanism. It includes a handrail tube transfer mechanism and a head and connecting flange transfer mechanism. The handrail tube transfer mechanism includes a transverse feeding component and a longitudinal feeding component. The transverse feeding component is fixedly installed on the inner wall of the support frame (11), and the longitudinal feeding component is fixedly installed on the top of the transverse feeding component. The head and connecting flange transfer mechanism includes a rotation and feeding component. The rotation and feeding component is fixedly installed on the inner wall of the support frame (11), and the output end of the rotation and feeding component is fixedly connected to a clamping component.

2. The automatic welding equipment for bus handrail flanges and end caps according to claim 1, characterized in that: The control terminal (14) is fixedly installed on the surface of the support frame (11). The upper end of the inner cavity of the support frame (11) is set as a processing cavity (12). The front and rear sides of the processing cavity (12) are connected to protective doors (13) by hinges. The bottom of the inner cavity of the processing cavity (12) is respectively placed with a handrail tube tray (15), a head and connecting flange tray (16) and a finished product tray (17).

3. The automatic welding equipment for bus handrail flanges and end caps according to claim 2, characterized in that: The first pneumatic clamping assembly (22) includes an air inlet (221), the top of which is fixedly connected to the end of the first six-axis robotic arm (21). Air chambers (222) are provided on both sides of the air inlet (221). A pneumatic system is connected to one side of the inner cavity of the air chamber (222). A piston (223) is slidably connected to the end of the air chamber (222). A telescopic rod (224) is fixedly connected to one side of the piston (223). A mounting bracket (225) is fixedly connected to the end of the telescopic rod (224). The end of the mounting bracket (225) is fixedly connected to one side of the handrail tube clamping head (23).

4. The automatic welding equipment for bus handrail flanges and end caps according to claim 3, characterized in that: The transverse feed assembly includes a first guide rail (41), the bottom of the first guide rail (41) is fixedly connected to the bottom of the inner cavity of the processing cavity (12), a first slider (42) is slidably connected to the surface of the first guide rail (41), a first lead screw (43) is threadedly connected to the inside of the first slider (42), a first motor (44) is fixedly connected to the end of the first lead screw (43), and the first motor (44) is fixedly installed at the bottom of the inner cavity of the processing cavity (12).

5. The automatic welding equipment for bus handrail flanges and end caps according to claim 4, characterized in that: The longitudinal feeding assembly includes a second guide rail (45), a second slider (46) is slidably connected to the surface of the second guide rail (45), a second lead screw (47) is threadedly connected to the inside of the second slider (46), a second motor (48) is provided at the end of the second lead screw (47), a handrail tube clamp (49) is fixedly connected to the top of the second slider (46), a turning wheel (410) is rotatably connected inside the handrail tube clamp (49) through a rotating shaft, and a turning motor (411) is provided at the end of the rotating shaft.

6. The automatic welding equipment for bus handrail flanges and end caps according to claim 5, characterized in that: The rotation and feed assembly includes a third slide rail (51), which is fixedly installed at the bottom of the inner cavity of the machining chamber (12). A third slider (52) is slidably connected to the surface of the third slide rail (51). A third lead screw (53) is threadedly connected to the inside of the third slider (52). A third motor (54) is fixedly connected to the end of the third lead screw (53). A synchronous motor (55) is fixedly connected to one side of the upper end of the third slider (52). A flipping frame (56) is fixedly connected to the output end of the synchronous motor (55).

7. The automatic welding equipment for bus handrail flanges and end caps according to claim 6, characterized in that: The clamping assembly includes a first air supply chamber (57) and a second air supply chamber (58). The first air supply chamber (57) and the second air supply chamber (58) are each divided into two sections and are respectively disposed inside the third slider (52) and the flipping frame (56). The first air supply chamber (57) and the second air supply chamber (58) inside the flipping frame (56) are annular and extend to their ends. The first air supply chamber (57) and the second air supply chamber (58) inside the third slider (52) are both externally connected to a pneumatic system. The ends of the first air supply chamber (57) and the second air supply chamber (58) are slidably connected to a piston rod (59). The end of the piston rod (59) is fixedly connected to a concave clamping head (510). The inner wall of the concave clamping head (510) is overlapped with a welded part (511).

8. The automatic welding equipment for bus handrail flanges and end caps according to claim 7, characterized in that: It also includes a wire filling and welding mechanism, which guides the welding wire to the outer splice gap and performs welding. The wire filling and welding mechanism includes a third six-axis robotic arm (61). The upper end of the third six-axis robotic arm (61) is fixedly connected to the top of the inner cavity of the processing chamber (12). The end of the third six-axis robotic arm (61) is fixedly connected to a tungsten inert gas (TIG) welding machine (62). The lower end of the TIG welding machine (62) is provided with an argon gas nozzle and a tungsten electrode. A mounting plate (63) is fixedly installed on the surface of the TIG welding machine (62). A mounting shaft (64) is fixedly connected to one side of the mounting plate (63). A welding wire coil (65) is rotatably connected to the surface of the mounting shaft (64). A mounting knob is threadedly connected to the end of the mounting shaft (64). The mounting plate (63) is fixedly connected to the mounting shaft (64). A wire feeding motor (66) is fixedly connected to one side of the mounting plate (63), and a wire feeding roller (67) is fixedly connected to the end of the shaft of the wire feeding motor (66). A sliding groove (68) is opened on the surface of the mounting plate (63). A sliding block (69) is slidably connected to the inner wall of the sliding groove (68). A spring (610) is fixedly connected to one end of the sliding block (69), and the other end of the spring (610) is fixedly connected to one end of the inner cavity of the sliding groove (68). A clamping roller (611) is rotatably connected to one side of the sliding block (69). The wire filling and welding mechanism also includes a welding wire guide tube (612) and a visual guidance camera (613). The welding wire guide tube (612) is fixedly connected to the surface of the tungsten inert gas welding machine (62) through a fastener. Three sets of visual guidance cameras (613) are provided.

9. The automatic welding equipment for bus handrail flanges and end caps according to claim 8, characterized in that: The control terminal (14) has a built-in PLC main controller, machine vision processing module, multi-axis servo drive module, pneumatic solenoid valve control module, welding process parameter adjustment module, industrial touch screen human-machine interaction module, and fault diagnosis and data storage module. The PLC main controller is connected to the controllers of the first six-axis robotic arm (21), the second six-axis robotic arm (31), and the third six-axis robotic arm (61) via EtherCAT industrial bus. It is also connected to the drivers of the first motor (44), the second motor (48), the third motor (54), the tilting motor (411), the synchronous motor (55), the wire feeding motor (66), the pneumatic system solenoid valve group, and the control interface of the tungsten inert gas welding machine (62) via hard wires. The machine vision processing module is connected to three sets of vision guidance cameras (613) via gigabit Ethernet. It is used to extract workpiece contour features, calculate spatial coordinates, detect the width and coaxiality of the butt joint gap, and transmit the positioning deviation and welding path compensation data to the PLC main controller in real time. The multi-axis servo drive module is integrated into the PLC main controller. Inside the controller, differential pulse signals are output to precisely control the speed, displacement, and start / stop sequence of each servo motor; the pneumatic solenoid valve control module controls the opening and closing of different air paths and the air pressure to adjust the clamping pressure and action speed of the first pneumatic clamping assembly (22), the second pneumatic clamping assembly (32), the first air supply chamber (57), and the second air supply chamber (58), respectively; the welding process parameter control module collects the output current, voltage, wire feeding speed, and argon flow signals of the tungsten inert gas welding machine (62) in real time, compares them with the preset process curve, and performs closed-loop adjustment; the industrial touch screen human-machine interaction module is used to input welding process parameters of different specifications of handrails, switch between automatic and manual operation modes, and display the real-time operating status and production statistics of the equipment; the fault diagnosis and data storage module monitors the operating signals of each sensor and actuator in real time. When the workpiece positioning deviation exceeds the limit, the welding current is abnormal, the pneumatic pressure is insufficient, or the motor is overloaded, it immediately triggers an audible and visual alarm and controls the equipment to stop safely. At the same time, it automatically records the fault code, the time of occurrence, and the corresponding welding parameters.

10. An automatic welding equipment for bus handrail flanges and end caps according to claim 9, characterized in that: The full-process collaborative control logic of the control terminal (14) is executed according to the following steps: System initialization: The PLC main controller sends a reset command to control all robotic arms and transfer mechanisms to return to their original positions, the pneumatic system is pressurized to the set pressure, the welding system completes self-test, and at the same time reads the dimensional parameters and corresponding welding process parameters of the handrail tube, end cap and flange to be processed from the industrial touch screen; Automatic feeding: The visual guidance camera (613) at the bottom of the second pneumatic clamping assembly (32) captures images of the end cap and connecting flange tray (16). The machine vision processing module identifies and calculates the center coordinates and angles of each workpiece. The PLC main controller controls the second six-axis robotic arm (31) to move the second pneumatic clamping assembly (32) to the corresponding position. The pneumatic solenoid valve control module drives the second pneumatic clamping assembly (32) to clamp the workpiece and place it at the end of the flipping frame (56) of the end cap and connecting flange transfer mechanism. The first air supply chamber (57) and the second air supply chamber (58) ventilate to drive the piston rod (59) to extend and drive the concave clamping head (510) to clamp the workpiece. Then, the visual guidance camera (613) at the bottom of the first pneumatic clamping assembly (22) positions the handrail tube in the handrail tube tray (15). The PLC main controller controls the first six-axis robotic arm (21) to grab the handrail tube and place it on the handrail tube clamping part (49) of the handrail tube transfer mechanism. Precise docking: The PLC main controller controls the first motor (44) to drive the first slider (42) to move along the first guide rail (41) to the welding station, and controls the third motor (54) to drive the third slider (52) to move along the third guide rail (51) to the corresponding docking position; the visual guidance camera (613) inside the fixing component takes pictures of the docking end face of the handrail tube and the end cap or flange, the machine vision processing module calculates the coaxiality deviation and end face gap of the two, the PLC main controller controls the second motor (48) to drive the second slider (46) to make X-axis fine adjustment along the second guide rail (45), and controls the flipping motor (411) and the synchronous motor (55) to drive the handrail tube and the end cap or flange to rotate to the same angle until the docking gap is controlled within the range of 0.2-0.5mm; Closed-loop welding: The PLC main controller controls the third six-axis robotic arm (61) to drive the tungsten inert gas welding machine (62) to move to the welding start point. The welding process parameter control module starts the welding machine and outputs the preset arc starting current. The wire feeding motor (66) feeds the wire at the set speed. During the welding process, the visual guidance camera (613) tracks the position of the weld pool and the gap in real time. The PLC main controller corrects the movement trajectory of the third six-axis robotic arm (61) in real time according to the feedback signal. At the same time, the welding process parameter control module automatically adjusts the welding current and wire feeding speed according to the welding position. After completing the 360° circumferential weld, the arc is automatically extinguished and the argon gas is turned off. Finished product unloading: After welding is completed, the PLC main controller controls the release of the workpiece by the head and connecting flange transfer mechanism, and controls the handrail tube transfer mechanism to drive the finished product back to the unloading position. The first six-axis robotic arm (21) grabs the finished handrail and places it into the finished product tray (17). All mechanisms are reset to the origin and ready to enter the next work cycle.

Images