A magnetic separator media box welding device and process method

Abstract

The application discloses a magnetic separator medium box welding device and process method, and belongs to the technical field of magnetic separator medium box welding. The device comprises a control unit of whole machine control, a rack, a laser welding module and a top surface fluctuation acquisition unit. The control unit is internally provided with a data entry module, a motion path control module, a path compensation calculation module, a path calculation module and a laser welding control module. A Y-direction transposition electric sliding table is fixedly arranged in the middle of the top surface of the rack. A medium box bearing platform is fixedly arranged on the sliding block of the Y-direction transposition electric sliding table. The magnetic separator medium box welding device and process method adopt a double symmetrical welding sequence, so that the deformation stress in the Z-axis and Y-axis directions is offset, the welding deformation is greatly reduced from the source, the overall sinking amount of the medium box is measured in real time through a displacement monitoring unit, high-precision full-closed-loop compensation is realized, and the automatic welding of the medium box to be welded is high in efficiency and high in quality.

Description

Technical Field

[0001] This invention specifically relates to a welding device and process for a magnetic separator media box, belonging to the field of magnetic separator media box welding technology. Background Technology

[0002] The media box, as a core and consumable component of the magnetic separator, has a large annual demand; the structure of the media box before welding is shown in the attached figure. Figure 1 As shown, it consists of 3 or 4 thin steel plates (generally 1mm-3mm) with densely packed circular holes and a thin metal rod (generally 1mm-8mm in diameter) penetrating all the steel plates. The metal rod extends a certain distance (generally 1mm-5mm) into the circular hole of the outermost steel plate. The welding work involves melting the extended portion of the metal rod and fusing it together with the steel plates on both sides to form a stable structure. The difficulties of this welding work are as follows: 1. The steel plate is very thin and has dense holes. There are gaps between the holes and the round bar. If the energy is not controlled properly during welding, the steel plate may be welded through. 2. Due to the low structural strength of the media box, the deformation during welding is relatively large. In order to ensure the welding is formed, the round bar tends to shrink and be pulled out on the other side when welding on one side in the horizontal direction. Therefore, it is necessary to process and install a device to forcibly constrain the position of the media box. 3. In order to ensure consistent deformation, the welding process is very demanding when the steel plates on both sides are placed on a vertical plane and welded at the same time. The molten pool is prone to falling, resulting in poor weld formation. In some cases, the molten metal rods may fail to fuse with the plates after falling. 4. When using automated welding, due to welding deformation, it is difficult to align the travel trajectory with the metal rod for welding. 5. Traditional arc welding process results in insufficient surface smoothness after welding, requiring a large amount of grinding work. Summary of the Invention

[0003] To address the aforementioned issues, this invention proposes a welding device and process for a magnetic separator media box. Employing a dual-symmetric welding sequence, the deformation stresses in the Z and Y axes cancel each other out, significantly reducing welding deformation at the source. Furthermore, by using a displacement monitoring unit to measure the overall subsidence of the media box in real time, high-precision closed-loop compensation can be achieved, enabling efficient and high-quality automatic welding of the media box to be welded.

[0004] The magnetic separator media box welding device of the present invention includes: The control unit for overall machine control includes a data input module, a motion path control module, a path compensation calculation module, a path calculation module, and a laser welding control module. The data entry module inputs the geometric dimensions of the medium box to be welded. The path calculation module unifies the geometric dimensions and the preset welding path. The welding path provides the welding sequence, and the geometric dimensions provide the welding coordinates under the welding path. At the same time, the path calculation module calculates the laser welding parameters based on the geometric dimensions. Finally, the motion path control module controls the Y-axis displacement electric slide and the two-axis electric slide according to the welding path to achieve position response. Meanwhile, the laser welding control module outputs the laser welding parameters corresponding to each point. After welding a row, the path compensation calculation module performs path compensation. A frame is provided, with a Y-axis transposition electric slide fixed in the middle of the top surface of the frame. A media cartridge carrying platform is fixed on the slider of the Y-axis transposition electric slide. A first grating ruler is provided between the slider and the slide base of the Y-axis transposition electric slide. The Y-axis transposition electric slide drives the media cartridge carrying platform to move linearly along the Y-axis, thereby causing the media cartridge carrying platform to move synchronously. A laser welding module is fixed to the top surface of a frame. The module includes a first laser welding unit and a second laser welding unit disposed on both sides of a media box support platform. Each unit includes a two-axis electric slide table in the X and Z directions. A Y-axis compensating electric slide table is fixed to the end slider of each slide table. A laser welding actuator is fixed to the slider of the Y-axis compensating electric slide table. A second grating ruler is disposed between the slider and the slide block of the Y-axis compensating electric slide table. The two-axis electric slide table can drive the first and second laser welding units to move in the X and Z directions. During X-axis movement, the focal length between the laser welding actuator and the media box to be welded can be adjusted. The Y-axis compensating electric slide table can respond to Y-axis offset correction and can also serve as a welding stepper for multiple adjacent metal rods. After the Y-axis shifting electric slide table steps to a position, the Y-axis compensating electric slide table completes the welding of multiple metal rods corresponding to that position. Laser welding actuators all include a laser generator and a laser welding torch. The laser welding torch is a galvanometer scanning type with a scanning range of 5mm×5mm and a scanning speed of 1000mm / s-5000mm / s. It adopts a circular spiral scanning trajectory, with the laser spot moving spirally from the center of the metal rod outwards. It first melts the root to form a weld nugget, and then gradually fills the surface, ensuring a uniform temperature distribution in the weld pool and avoiding localized overheating that could lead to a large weld pool. The laser welding torch is equipped with a coaxial auxiliary air blowing device, with the air blowing direction tilted upwards at 15 to 30 degrees and the air pressure at 0.1 to 0.3 MPa. The mechanical force of the airflow directly supports the weld pool, preventing it from sagging and simultaneously preventing weld oxidation. The laser welding torch uses... The pulsed defocus laser welding method uses the following pulse parameters: peak power 1500W-3000W, pulse width 0.5ms-5ms, pulse frequency 50Hz-200Hz, and duty cycle 10%-30%. The pulsed laser operates in a high-energy pulse-intermittent cooling mode, with each pulse generating only a tiny molten pool. The molten pool solidifies rapidly within the pulse interval, preventing the liquid metal from falling. The defocusing amount is set to 1mm to 3mm, placing the laser focus above the protruding end of the metal rod. Because the metal rod protrudes from the steel plate surface, the defocus welding has a more significant heating effect on the metal rod, while the heat input to the steel plate is relatively small, thus reducing the likelihood of weld penetration. The top surface fluctuation acquisition unit comprises two sets, which are mounted on the top of the medium box to be welded via a bracket. The acquisition end of the top surface fluctuation acquisition unit faces the top surface of the steel plate to be welded. The top surface fluctuation acquisition unit includes two sets of displacement monitoring units, which are fixed on both sides of the frame and located on both sides of the laser welding actuator.

[0005] The magnetic separator media box welding device of this invention abandons the traditional arc welding process (TIG, MIG) and adopts laser welding and simultaneous double-sided welding. Laser welding, due to its high energy concentration, concentrated heat input, and small molten pool, achieves high-speed welding without molten pool sagging or flowing. During the welding process, laser defocusing welding is used. Because the metal rod protrudes from the steel plate, the heating effect on the metal rod is more obvious, thus reducing the likelihood of weld penetration. Because of simultaneous double-sided welding, the heat input is symmetrical, and both ends of the metal rod melt simultaneously, preventing deformation that could lead to asymmetry. This solves the problem of needing strong constraints to prevent deformation during welding. This invention addresses the shape issue, thus achieving free-state welding. The magnetic separator media box welding device of this invention adopts a 5-axis coordinate welding method. The media box bearing platform in the middle of the frame loads the media box to be welded, and a set of laser welding actuators is set on each side. Each set of laser welding actuators has two degrees of freedom of movement: up, down, left, and right. The left and right movement of the laser welding actuators is used to adapt to the focal length adjustment of the media box without providing width, and the up and down movement of the laser welding actuators is used to weld metal rods of different heights on the media box to be welded. The Y-axis displacement electric slide can drive the media box to be welded to move back and forth. The media box to be welded can achieve forward and backward movement relative to the two sets of laser welding actuators. Regarding motion, the control unit's main tasks are twofold: first, controlling each motion axis to achieve precise motion paths; second, controlling the laser welding actuator. Since the metal rods of the welding medium box are arranged in multiple rows, the spacing between each row varies. Therefore, the control unit can define the coordinates of the start and end points of each row through parameterized settings, thereby achieving welding for each row. Because the diameter of the metal rods in each row varies, the speed of each row can be adjusted independently. The diameter of the metal rods in the welding medium box and the temperature rise of the workpiece during welding require adjustments to the laser power; therefore, the control unit... The control unit can also adjust the laser power, galvanometer vibration mode, and width. Since the welding medium box will shrink and deform during the welding process, the control unit has added a path compensation calculation module to address the welding shrinkage deformation. During welding, the middle, top, and bottom three rows of metal rods are welded first to create a stable structure for the medium box. Then, welding proceeds from top to bottom. At this point, the shrinkage deformation of the weld is from top to bottom and will not affect the position of the unwelded welds. Furthermore, during welding, the path compensation calculation module calculates the shrinkage amount after welding, and the control unit performs coordinate compensation for the welding shrinkage amount, thereby achieving precise welding.

[0006] Furthermore, the bracket spans both ends of the Y-axis transposition electric slide, and the top surface fluctuation acquisition unit is fixed in the middle of the top surface of the bracket; the bracket forms a gantry frame, which is used to mount the top surface fluctuation acquisition unit above the media box support platform.

[0007] Furthermore, the bracket includes a right-angle arm with a right-angle groove on its inner side; the right-angle groove engages with the Z-axis slide of the two-axis electric slide and is secured with bolts; the top surface fluctuation acquisition unit is fixed to the front end of the top of the right-angle arm; the bracket can be mounted on the Z-axis slide of the two-axis electric slide and does not restrict the normal sliding of the Z-axis slider of the two-axis electric slide; the bracket can mount the top surface fluctuation acquisition unit above the media box support platform.

[0008] Furthermore, the top surface of the media box carrying platform is provided with a media box slot, and cylinder seats are provided at both ends of the media box slot on the media box carrying platform. A locking cylinder is fixed on the cylinder seat, and a pressure plate is fixed to the telescopic end of the locking cylinder. In use, each metal plate of the media box to be welded is clamped into the inside of the media box slot. Then, the locking cylinder is activated, driving the pressure plate to move towards each metal plate, which can press and limit the metal plate on both sides.

[0009] Furthermore, the displacement monitoring unit includes an outer slide rail and an inner slide rail, both ends of which are fixed with end caps; the inner slide rail is slidably installed with the outer slide rail, and an adjusting cylinder is fixed between the top inner side of the outer slide rail and the top outer side of the inner slide rail; a floating seat is slidably arranged between the inner slide rails, and a third grating ruler is installed between the inner slide rail and the floating seat; a sliding column is slidably arranged on the floating seat, and both ends of the sliding column are fixed to the end caps; a spring body is sleeved on the outside of the sliding column, and the spring body is arranged between the end caps and the top of the floating seat; a sliding sleeve is fixed to the floating seat by a support foot, and a right-angled detection arm is slidably arranged on the sliding sleeve; the sliding sleeve and the detection arm are locked together by multiple bolts, and a detection rod is fixed to the bottom of the detection arm.

[0010] During operation, the inner slide rail is driven by the adjusting cylinder to slide linearly down the outer slide rail until the bottom surface of the inner slide rail is pressed against the end cap and stops. At this time, the detection rod is in contact with the top surface of the medium box to be welded. As the medium box to be welded moves along the Y direction, the fluctuation of the top surface of the medium box to be welded is collected by the third grating ruler. Specifically, when the top surface of the medium box to be welded fluctuates, the detection rod slides up and down linearly in sync, thereby allowing the detection arm, sliding sleeve and floating seat to slide linearly along the inner slide rail in sync. When the floating seat slides, it drives the reading head of the third grating ruler to slide up and down synchronously. The reading head associates the data read (Z direction data) with the first grating ruler (Y direction data) to form a fluctuation curve.

[0011] Furthermore, the displacement monitoring unit is a laser displacement sensor, which is a diffuse reflection laser displacement sensor with a resolution of 0.001mm and a sampling frequency of 100Hz. A transparent acrylic protective plate is fixed below the laser displacement sensor.

[0012] A welding process for a magnetic separator media box, employing a magnetic separator media box welding device, is described in detail below: S1: Medium box loading: Place the medium box to be welded on the medium box support platform and quickly lock the medium box to be welded in place; S2: Inputting dielectric box parameters: Input the geometric parameters of the dielectric box to be welded through the data input module. The geometric parameters include the number of rows, columns, row spacing, column spacing, diameter, and extension length of the metal rod. S3: Welding process generation: After obtaining the diameter of the metal rod, the path calculation module generates welding process parameters that correspond one-to-one with the diameter of the metal rod. The welding parameters include laser power, welding speed, defocusing amount, and pulse parameters. Then, the path calculation module automatically generates the welding process based on the dielectric cell parameters and welding parameters. The welding process includes the welding path and a process parameter table. S4: Welding Start: According to the welding process, the Y-axis shifting electric slide and the Z-axis slide of the two-axis electric slide are precisely aligned with the metal rod to be initially welded. Then, the X-axis slide of the two-axis electric slide drives the laser welding actuator to move towards the medium box to be welded, so that the laser welding actuator and the medium box to be welded are adjusted to the target focal length. Then, according to the process parameter table, the controller controls the first laser welding unit and the second laser welding unit to weld the two end faces of the medium box to be welded simultaneously. After the welding of one metal rod is completed, the laser welding actuator is shifted to the next metal rod according to the welding path. The Z-axis slide of the two-axis electric slide drives the laser welding actuator to change rows, and the Y-axis shifting electric slide drives the medium box carrying platform to change columns, so that the laser welding actuator is aligned with the next metal rod to be welded, and the welding of one row of metal rods is completed in sequence. S5: Path Compensation: After a row of metal rods is welded, the path compensation calculation module obtains the fluctuation value of the top surface of the medium box to be welded through the top surface fluctuation acquisition unit, and compensates the welding path according to the fluctuation value to generate a new welding path. The controller then welds other rows of metal rods according to the new welding path. S6: Welding and unloading. After welding is completed, the media box carrying platform drives the media box back to the initial position and removes the welded media box.

[0013] Furthermore, the welding path generation is specifically as follows: After obtaining the media box parameters, the controller generates the welding path based on the media box's geometric parameters and a path planning method. The path planning method is a double-symmetric welding sequence, as detailed below: Z-axis direction: Divide all metal bar rows in half from the middle, weld the middle row first, then weld the top and bottom rows of metal bars in sequence to complete the support system welding. Next, complete the welding of all rows of metal bars from top to bottom; when the number of metal bar rows is even, complete the welding of the middle two rows from top to bottom. Y-axis direction: When welding the support system, the metal bars in the same row are first welded to the metal bars in the middle column of that row, and then the welding is carried out alternately from the middle to both sides until all the metal bars in that row are welded.

[0014] Furthermore, the path compensation process is as follows: S51. Before welding, the displacement monitoring unit automatically measures the initial top surface height of the medium box to be welded; S52. During the welding process, the displacement monitoring unit measures the current top surface height in real time; S53. The path compensation calculation module automatically calculates the Z-axis offset of the laser welding actuator, that is, the initial top surface height minus the current top surface height; S54. After each row is welded, the controller adjusts the Z-axis coordinate of the laser welding actuator according to the current Z-axis offset, and then proceeds to weld the next row.

[0015] Furthermore, when the number of columns of the medium box to be welded is greater than 30, a Y-axis warping compensation step is also included: Before welding, the medium box carrying platform drives the medium box to be welded to move in the Y-axis direction, and the displacement monitoring unit scans the entire top surface of the medium box to obtain the initial height curve; after welding 5-10 rows of metal rods, the scan is repeated once to obtain the current height curve; the path compensation calculation module calculates the Y-coordinate offset and Z-coordinate offset based on the current height curve and the initial height curve; the controller controls the Z-axis slide and the Y-axis compensation electric slide of the two-axis electric slide to correct the offset.

[0016] Compared with the prior art, the magnetic separator medium box welding device and process method of the present invention have the following advantages: 1. This invention abandons the traditional arc welding process and adopts pulsed laser welding process. It utilizes the characteristics of high laser energy concentration, concentrated heat input and small molten pool to achieve high-speed welding, and at the same time completely solves the problem of molten pool falling and flowing when welding vertical plane.

[0017] 2. This invention adopts a double-sided simultaneous welding method with symmetrical heat input. Both ends of the metal rod melt and solidify at the same time, avoiding the problem of deformation that leads to asymmetry on both sides. This enables the welding of the medium box in a free state without the need for complex forced constraint tooling.

[0018] 3. The present invention uses a defocused laser welding method, which has a more obvious heating effect on the metal rod, while the heat input to the thin steel plate is relatively small, effectively avoiding the situation of welding through the steel plate.

[0019] 4. The present invention adopts a double symmetrical welding sequence, which makes the welding shrinkage deformation self-cancel, thus greatly reducing the welding deformation from the source.

[0020] 5. This invention uses a single-top-surface laser displacement sensor with full closed-loop compensation, achieving a compensation accuracy of ±0.03mm, which completely solves the problem of trajectory misalignment caused by welding deformation.

[0021] 6. The weld surface after welding is smooth and flat, eliminating the need for subsequent grinding, which greatly reduces production costs and production cycle.

[0022] 7. This invention adopts a parametric programmable control system, which can adapt to the welding requirements of different specifications of media boxes. It has strong versatility, high degree of automation, and welding efficiency is 4-5 times higher than that of traditional arc welding process. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the medium box to be welded according to the present invention.

[0024] Figure 2 For the present invention Figure 1 A magnified schematic diagram of the structure at point A in the middle.

[0025] Figure 3 This is a schematic diagram of the overall structure of the magnetic separator medium box welding device of the present invention.

[0026] Figure 4 This is a schematic diagram of the overall structure of the media box carrying platform of the present invention.

[0027] Figure 5 This is a schematic diagram of the installation structure of the laser welding module and displacement monitoring unit of the present invention.

[0028] Figure 6 This is a schematic diagram of the overall structure of the displacement monitoring unit of the present invention.

[0029] Reference numerals: 1. Frame, 2. Y-axis shifting electric slide, 3. Media box carrying platform, 4. First grating ruler, 5. Second-axis electric slide, 6. Y-axis compensating electric slide, 7. Laser welding actuator, 8. Support, 9. Displacement monitoring unit, 10. Media box slot, 11. Cylinder seat, 12. Locking cylinder, 13. Pressure plate, 14. Outer slide rail, 15. Inner slide rail, 16. End cap, 17. Adjustment cylinder, 18. Floating seat, 19. Third grating ruler, 20. Sliding column, 21. Spring body, 22. Sliding sleeve, 23. Detection arm, 24. Detection rod. Detailed Implementation

[0030] Example 1: like Figures 1 to 6 The magnetic separator media box welding device shown includes: The control unit for overall machine control includes a data input module, a motion path control module, a path compensation calculation module, a path calculation module, and a laser welding control module. The data entry module inputs the geometric dimensions of the medium box to be welded. The path calculation module unifies the geometric dimensions and the preset welding path. The welding path provides the welding sequence, and the geometric dimensions provide the welding coordinates under the welding path. At the same time, the path calculation module calculates the laser welding parameters based on the geometric dimensions. Finally, the motion path control module controls the Y-axis displacement electric slide and the two-axis electric slide according to the welding path to achieve position response. Meanwhile, the laser welding control module outputs the laser welding parameters corresponding to each point. After welding a row, the path compensation calculation module performs path compensation. A frame 1 is provided, and a Y-axis transposition electric slide 2 is fixed in the middle of the top surface of the frame 1. A media box carrying platform 3 is fixed on the slider of the Y-axis transposition electric slide 2. A first grating ruler 4 is provided between the slider and the slide base of the Y-axis transposition electric slide 2. The Y-axis transposition electric slide 2 drives the media box carrying platform 3 to move linearly along the Y-axis, thereby driving the media box carrying platform 3 to move synchronously. A laser welding module is fixed to the top surface of a frame 1. The laser welding module includes a first laser welding unit and a second laser welding unit disposed on both sides of a media box support platform 3. The first and second laser welding units each include a two-axis electric slide 5 in the X and Z directions. A Y-axis compensation electric slide 6 is fixed to the end slider of the two-axis electric slide 5. A laser welding actuator 7 is fixed to the slider of the Y-axis compensation electric slide 6. A second grating ruler is disposed between the slider and the slide base of the Y-axis compensation electric slide 6. The two-axis electric slide 5 can drive the first and second laser welding units to move in the X and Z directions. When moving in the X direction, it can adjust the focal length between the laser welding actuator 7 and the media box to be welded. The Y-axis compensation electric slide 6 can respond to the Y-axis offset correction and can also serve as a welding step for multiple adjacent metal rods. After the Y-axis transposition electric slide 2 steps to a position, the Y-axis compensation electric slide 6 completes the welding of multiple metal rods corresponding to that position. Each laser welding actuator 7 includes a laser generator and a laser welding torch. The laser welding torch is a galvanometer scanning type with a scanning range of 5mm×5mm and a scanning speed of 1000mm / s-5000mm / s. It adopts a circular spiral scanning trajectory, with the laser spot moving spirally from the center of the metal rod outwards. It first melts the root to form a weld nugget, and then gradually fills the surface, ensuring a uniform temperature distribution in the molten pool and preventing localized overheating that could lead to a large molten pool. The laser welding torch is equipped with a coaxial auxiliary air blowing device, with the air blowing direction tilted upwards at 15 to 30 degrees and the air pressure at 0.1 to 0.3 MPa. The mechanical force of the airflow can directly support the molten pool, preventing it from sagging and simultaneously preventing weld oxidation. The laser welding torch adopts... The pulsed defocus laser welding method uses the following pulse parameters: peak power 1500W-3000W, pulse width 0.5ms-5ms, pulse frequency 50Hz-200Hz, and duty cycle 10%-30%. The pulsed laser operates in a high-energy pulse-intermittent cooling mode, with each pulse generating only a tiny molten pool. The molten pool solidifies rapidly within the pulse interval, preventing the liquid metal from falling. The defocusing amount is set to 1mm to 3mm, placing the laser focus above the protruding end of the metal rod. Because the metal rod protrudes from the steel plate surface, the defocus welding has a more significant heating effect on the metal rod, while the heat input to the steel plate is relatively small, thus reducing the likelihood of weld penetration. The top surface fluctuation acquisition unit consists of two sets. The top surface fluctuation acquisition unit is mounted above the medium box to be welded via a bracket 8. The acquisition end of the top surface fluctuation acquisition unit faces the top surface of the steel plate to be welded. The top surface fluctuation acquisition unit includes two sets of displacement monitoring units 9. The two sets of displacement monitoring units 9 are fixed on both sides of the frame 1 and are located on both sides of the laser welding actuator 7.

[0031] Through extensive process experiments, this invention has discovered that under the standard row-by-row welding process, the welding shrinkage deformation of the magnetic separator media box exhibits significant directional characteristics: shrinkage in the Z-axis direction is cumulative, with the total shrinkage equal to the sum of the shrinkage in each row; while shrinkage in the Y-axis direction is localized, with the total shrinkage only equal to the shrinkage of a single metal rod. Therefore, over 95% of the welding deformation is concentrated in the Z-axis direction, while only minor overall warping deformation exists in large-size media boxes in the Y-axis direction. Based on this discovery, this invention employs a double-symmetrical welding sequence to cancel out the deformation stresses in the Z-axis and Y-axis directions, significantly reducing welding deformation from the source. Simultaneously, this is achieved using only a single displacement monitoring unit mounted on the top surface. Real-time measurement of the overall sinking of the media box enables high-precision closed-loop compensation. The magnetic separator media box welding device of this invention abandons traditional arc welding processes (TIG, MIG) and adopts laser welding and simultaneous double-sided welding. Laser welding, due to its high energy concentration, concentrated heat input, and small molten pool, achieves high-speed welding without molten pool sagging or flowing. During welding, laser defocusing welding is used; because the metal rod protrudes from the steel plate, the heating effect on the metal rod is more pronounced, thus reducing the likelihood of weld penetration. Because of simultaneous double-sided welding, the heat input is symmetrical, and both ends of the metal rod melt simultaneously, preventing deformation and asymmetry, thereby solving the welding problem. The problem of strong constraint placement deformation is solved, thus achieving free state welding. The magnetic separator medium box welding device of the present invention adopts 5-axis coordinate welding. The medium box bearing platform 3 in the middle of the frame 1 loads the medium box to be welded. A set of laser welding actuators 7 is set on each side. Each set of laser welding actuators 7 has two degrees of freedom of movement: up and down and left and right. The left and right movement of the laser welding actuators 7 is used to adapt to the focal length adjustment of the medium box without providing width. The up and down movement of the laser welding actuators 7 is used to weld metal rods of different heights of the medium box to be welded. The Y-axis displacement electric slide 2 can drive the medium box to be welded to move back and forth. The medium box to be welded can achieve relative back and forth movement with respect to the two sets of laser welding actuators 7. The control unit's main tasks are twofold: first, to control each motion axis to achieve precise motion paths; and second, to control the laser welding actuator 7. Since the metal rods of the welding medium box are arranged in multiple rows with varying spacing between rows, the control unit can define the coordinates of the start and end points of each row through parameterized settings, thereby achieving welding for each row. Because the diameter of each metal rod varies, the speed of each row can be adjusted independently. The diameter of the metal rods in the welding medium box and the temperature rise of the workpiece during welding require adjustments to the laser power; therefore, the control unit can also adjust the laser power, galvanometer vibration mode, and width.Because the medium box to be welded will shrink and deform during the welding process, the control unit has also added a path compensation calculation module to deal with the welding shrinkage deformation method. During welding, the middle row, the top row, and the bottom row of metal bars are welded first to create a stable structure for the medium box. Then, welding proceeds from top to bottom. At this time, the shrinkage deformation of the weld after welding is from top to bottom and will not affect the position of the unwelded welds. Moreover, during welding, the path compensation calculation module calculates the shrinkage amount after welding, and the control unit performs coordinate compensation for the welding shrinkage amount, thereby achieving precise welding.

[0032] The bracket 8 spans both ends of the Y-direction electric slide table 2, and the top surface fluctuation acquisition unit is fixed in the middle of the top surface of the bracket 8; the bracket 8 forms a gantry frame, which is used to mount the top surface fluctuation acquisition unit above the media box carrying platform 3.

[0033] The bracket 8 includes a right-angle arm with a right-angle groove on its inner side; the right-angle groove engages with the Z-axis slide of the two-axis electric slide table 5 and is secured with bolts; the top surface fluctuation acquisition unit is fixed to the front end of the top of the right-angle arm; the bracket 8 can be mounted on the Z-axis slide of the two-axis electric slide table 5 without restricting the normal sliding of the Z-axis slider of the two-axis electric slide table 5; the bracket 8 can mount the top surface fluctuation acquisition unit above the media box support platform 3.

[0034] The media box carrying platform 3 has a media box slot 10 on its top surface. The media box carrying platform 3 has cylinder seats 11 facing each other at both ends of the media box slot 10. A locking cylinder 12 is fixed on the cylinder seat 11. A pressure plate 13 is fixed to the telescopic end of the locking cylinder 12. In use, each metal plate of the media box to be welded is clamped into the inside of the media box slot 10. Then, the locking cylinder 12 is activated, driving the pressure plate 13 to move towards each metal plate, which can press and limit the metal plates on both sides.

[0035] The displacement monitoring unit 9 includes an outer slide rail 14 and an inner slide rail 15, both ends of which are fixed with end caps 16. The inner slide rail 15 is slidably installed with the outer slide rail 14, and an adjusting cylinder 17 is fixed between the top inner side of the outer slide rail 14 and the top outer side of the inner slide rail 15. A floating seat 18 is slidably arranged between the inner slide rails 15, and a third grating ruler 19 is installed between the inner slide rails 15 and the floating seat 18. A sliding column 20 is slidably mounted on the floating seat 18, with both ends of the sliding column 20 fixed to the end cap 16; a spring body 21 is sleeved on the outside of the sliding column 20, and the spring body 21 is located between the end cap 16 and the top of the floating seat 18; a sliding sleeve 22 is fixed to the floating seat 18 by a support foot, and a right-angled detection arm 23 is slidably mounted on the sliding sleeve 22, and the sliding sleeve 22 and the detection arm 23 are locked together by multiple bolts, and a detection rod 24 is fixed to the bottom of the detection arm 23.

[0036] During operation, the inner slide rail 15 is driven to slide linearly down the outer slide rail 14 by the adjusting cylinder 17 until the bottom surface of the inner slide rail 15 is pressed against the end cap 16 and then stops. At this time, the detection rod 24 is attached to the top surface of the medium box to be welded. As the medium box to be welded moves along the Y direction, the fluctuation of the top surface of the medium box to be welded is collected by the third grating ruler 19. Specifically, when the top surface of the medium box to be welded fluctuates, the detection rod 24 slides up and down linearly in sync, so that the detection arm 23, the sliding sleeve 22 and the floating seat 18 slide synchronously along the inner slide rail 15. When the floating seat 18 slides, it drives the reading head of the third grating ruler 19 to slide up and down synchronously. The reading head associates the data read (Z direction data) with the first grating ruler 4 (Y direction data) to form a fluctuation curve.

[0037] The displacement monitoring unit 9 is a laser displacement sensor, which is a diffuse reflection laser displacement sensor with a resolution of 0.001mm and a sampling frequency of 100Hz. A transparent acrylic protective plate is fixed below the laser displacement sensor.

[0038] A welding process for a magnetic separator media box, employing a magnetic separator media box welding device, is described in detail below: S1: Medium box loading: Place the medium box to be welded on the medium box carrying platform 3 and quickly lock the medium box to be welded in place; S2: Inputting dielectric box parameters: Input the geometric parameters of the dielectric box to be welded through the data input module. The geometric parameters include the number of rows, columns, row spacing, column spacing, diameter, and extension length of the metal rod. S3: Welding process generation: After obtaining the diameter of the metal rod, the path calculation module generates welding process parameters that correspond one-to-one with the diameter of the metal rod. The welding parameters include laser power, welding speed, defocusing amount, and pulse parameters. Then, the path calculation module automatically generates the welding process based on the dielectric cell parameters and welding parameters. The welding process includes the welding path and a process parameter table. S4: Welding Start: According to the welding process, the Y-axis shifting electric slide 2 and the Z-axis slide of the two-axis electric slide 5 are precisely aligned with the metal rod to be initially welded. Then, the X-axis slide of the two-axis electric slide 5 drives the laser welding actuator 7 to move towards the medium box to be welded, so that the laser welding actuator 7 and the medium box to be welded are adjusted to the target focal length. Then, according to the process parameter table, the controller controls the first laser welding unit and the second laser welding unit to weld the two end faces of the medium box to be welded simultaneously. After the welding of one metal rod is completed, the laser welding actuator 7 is shifted to the next metal rod according to the welding path. The Z-axis slide of the two-axis electric slide 5 drives the laser welding actuator 7 to change rows, and the Y-axis shifting electric slide 2 drives the medium box carrying platform 3 to change columns, so that the laser welding actuator 7 is aligned with the next metal rod to be welded, and the welding of one row of metal rods is completed in sequence. S5: Path Compensation: After a row of metal rods is welded, the path compensation calculation module obtains the fluctuation value of the top surface of the medium box to be welded through the top surface fluctuation acquisition unit, and compensates the welding path according to the fluctuation value to generate a new welding path. The controller then welds other rows of metal rods according to the new welding path. S6: Welding discharge. After welding is completed, the medium box carrying platform 3 drives the medium box back to the initial position and removes the welded medium box.

[0039] The welding path generation is as follows: After the controller obtains the medium box parameters, it generates the welding path based on the geometric parameters of the medium box and the path planning method. The path planning method is a double symmetrical welding sequence, as detailed below: Z-axis direction: Divide all metal bar rows in half from the middle, weld the middle row first, then weld the top and bottom rows of metal bars in sequence to complete the support system welding. Next, complete the welding of all rows of metal bars from top to bottom; when the number of metal bar rows is even, complete the welding of the middle two rows from top to bottom. Y-axis direction: When welding the support system, the metal bars in the same row are first welded to the metal bars in the middle column of that row, and then the welding is carried out alternately from the middle to both sides until all the metal bars in that row are welded.

[0040] The path compensation process is as follows: S51. Before welding, the displacement monitoring unit 9 automatically measures the initial top surface height of the medium box to be welded; S52. During the welding process, the displacement monitoring unit 9 measures the current top surface height in real time; S53. The path compensation calculation module automatically calculates the Z-axis offset of the laser welding actuator 7, which is the initial top surface height minus the current top surface height. S54. After each row is welded, the controller adjusts the Z-axis coordinate of the laser welding actuator 7 according to the current Z-axis offset, and then proceeds to weld the next row.

[0041] When the number of columns of the medium box to be welded is greater than 30, a Y-axis warping compensation step is also included: Before welding, the medium box bearing platform 3 drives the medium box to be welded to move in the Y-axis direction, and the displacement monitoring unit 9 scans the entire top surface of the medium box to obtain the initial height curve; after welding 5-10 rows of metal rods, the scan is repeated once to obtain the current height curve; the path compensation calculation module calculates the Y-coordinate offset and Z-coordinate offset based on the current height curve and the initial height curve; the controller controls the Z-axis slide of the two-axis electric slide 5 and the Y-axis compensation electric slide 6 to correct the offset.

[0042] Example 2: The welding process of the magnetic separator media box of the present invention is as follows: The magnetic separator media box to be welded consists of four thin steel plates with dense circular holes, each 2 mm thick, and a thin metal rod with a diameter of 3 mm that penetrates all the steel plates; the metal rod extends 2 mm into the circular hole of the outermost steel plate; the media box to be welded has 50 rows and 20 columns of metal rods, with a row spacing of 10 mm and a column spacing of 15 mm; The laser welding process for the magnetic separator media box described in this invention comprises the following steps: S1: Place the medium box to be welded on the medium box support platform 3, pass through and lock it to ensure that the position of the medium box to be welded is accurate; S2: Input the geometric parameters of the media box in the human-machine interface of the controller: 50 rows, 20 columns, row spacing 10mm, column spacing 15mm, metal rod diameter 3mm, extension length 2mm; S3: Input welding process parameters in the controller: peak power 2000W, pulse width 2ms, pulse frequency 100Hz, duty cycle 20%, welding speed 120mm / s, defocusing amount +2mm; S4: The controller automatically generates welding paths and process parameter tables based on the input parameters; S5: Start the welding process. Laser welding actuator 7 simultaneously moves to the middle row (25th row) and middle column (10th column) of the media box, and welds both the left and right end faces at the same time; the welding sequence is as follows: Z-axis direction: First weld row 25 (middle row), then weld row 1 (top) and row 50 (bottom), and finally, weld all rows from top to bottom. Y-axis direction: When welding rows 25, 1, and 50, weld column 10 (middle column) first, then weld columns 9, 11, 8, 12, and so on until columns 1 and 20 are welded; the remaining rows can be welded from left to right; during the welding process, a full closed-loop compensation method using the top surface fluctuation acquisition unit is used for real-time compensation. The specific steps are as follows: before welding, the top surface fluctuation acquisition unit automatically measures the initial top surface height H0 of the medium box to be 100.00 mm; during the welding process, the laser displacement sensor measures the current top surface height H(t) in real time at a frequency of 100 Hz, and the controller performs moving average filtering and outlier removal on the measured values: the average of 5 consecutive measurements is taken as the current... The height value is discarded if the deviation of a single measurement from the average exceeds 0.1mm. The controller automatically calculates the welding torch Z-axis offset ΔZ(t) = H0 - H(t). After each row is welded, the controller adjusts the Z-axis coordinates of the laser welding torches on both sides according to the current ΔZ(t) before welding the next row. For example, after welding the 25th row, the sensor measures the current top surface height H(t) = 99.95mm, then ΔZ(t) = 0.05mm, and the welding torch Z-axis coordinate shifts downward by 0.05mm. After welding the 24th and 26th rows, H(t) = 99.90mm, ΔZ(t) = 0.10mm, and the welding torch Z-axis coordinate shifts downward by another 0.05mm, and so on. Push; After all metal rods are welded, the Y-axis displacement electric slide 2 drives the medium box carrying platform 3 back to its initial position, and the operator removes the welded medium box; After testing, the magnetic separator medium box welded using the device and process of this invention has a welding deformation of less than 0.2mm, which is more than 90% lower than the traditional arc welding process; the weld fusion rate reaches 100%, with no defects such as weld penetration, incomplete welding, or molten pool sagging; the weld surface is smooth and flat, requiring no subsequent grinding; the welding efficiency reaches 5-6 medium boxes per hour, which is more than 5 times higher than the traditional arc welding process; the compensation accuracy is stable within ±0.03mm, and the welding quality consistency of different batches of workpieces reaches more than 99%; for ultra-large scales with 40 columns... For the medium box, based on the above, a Y-axis warpage compensation step is added: Before welding, the medium box support platform 3 moves the medium box uniformly from left to right in the Y-axis direction once, and the top surface fluctuation acquisition unit scans the entire top surface of the medium box simultaneously to obtain the initial height curve H0(y); after welding 5 rows, the scan is repeated once to obtain the current height curve H(t,y); the compensation amount ΔZ(y) = H0(y) - H(t,y) at each Y coordinate is calculated; when welding the next row, while the support platform moves in the Y-axis direction, the Z-axis coordinate of the welding torch is finely adjusted in real time according to ΔZ(y); after adopting this compensation method, the Y-axis warpage of the ultra-large medium box is controlled within 0.02mm, which fully meets the welding requirements.

[0043] The above embodiments are merely preferred embodiments of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention are included within the scope of the present invention.

Claims

1. A welding device for a magnetic separator media box, characterized in that: include: The control unit for overall machine control includes a data input module, a motion path control module, a path compensation calculation module, a path calculation module, and a laser welding control module. A frame, wherein a Y-axis transposition electric slide is fixed in the middle of the top surface of the frame, and a media box carrying platform is fixed on the slider of the Y-axis transposition electric slide; a first grating ruler is provided between the slider and the slide base of the Y-axis transposition electric slide. A laser welding module is fixed to the top surface of a frame. The module includes a first laser welding unit and a second laser welding unit disposed on both sides of a media box support platform. Each laser welding unit includes a two-axis electric slide table in the X and Z directions. A Y-axis compensating electric slide table is fixed to the end slider of each two-axis electric slide table. A laser welding actuator is fixed to the slider of the Y-axis compensating electric slide table. A second optical grating ruler is disposed between the slider and the slide base of the Y-axis compensating electric slide table. The top surface fluctuation acquisition unit comprises two sets, which are mounted on the top of the medium box to be welded via a bracket. The acquisition end of the top surface fluctuation acquisition unit faces the top surface of the steel plate to be welded. The top surface fluctuation acquisition unit includes two sets of displacement monitoring units, which are fixed on both sides of the frame and located on both sides of the laser welding actuator.

2. The magnetic separator medium box welding device according to claim 1, characterized in that: The bracket spans both ends of the Y-axis transposition electric slide, and the top surface fluctuation acquisition unit is fixed in the middle of the top surface of the bracket.

3. The magnetic separator medium box welding device according to claim 1, characterized in that: The bracket includes a right-angle arm with a right-angle groove on its inner side; the right-angle groove engages with the Z-axis slide of the two-axis electric slide table and is fastened with bolts; the top surface fluctuation acquisition unit is fixed to the front end of the top surface of the right-angle arm.

4. The magnetic separator medium box welding device according to claim 1, characterized in that: The media box carrying platform has a media box slot on its top surface. Cylinder seats are provided at both ends of the media box slot on the media box carrying platform. A locking cylinder is fixed on the cylinder seat, and a pressure plate is fixed to the telescopic end of the locking cylinder.

5. The magnetic separator medium box welding device according to claim 1, characterized in that: The displacement monitoring unit includes an outer slide rail and an inner slide rail, both ends of which are fixed with end caps. The inner slide rail is slidably installed with the outer slide rail, and an adjusting cylinder is fixed between the top inner side of the outer slide rail and the top outer side of the inner slide rail. A floating seat is slidably arranged between the inner slide rails, and a third grating ruler is installed between the inner slide rail and the floating seat. A sliding column is slidably arranged on the floating seat, and both ends of the sliding column are fixed to the end caps. A spring body is sleeved on the outside of the sliding column, and the spring body is arranged between the end caps and the top of the floating seat. A sliding sleeve is fixed to the floating seat by a support foot, and a right-angled detection arm is slidably arranged on the sliding sleeve. The sliding sleeve and the detection arm are locked together by multiple bolts, and a detection rod is fixed to the bottom of the detection arm.

6. The magnetic separator medium box welding device according to claim 1, characterized in that: The displacement monitoring unit is a laser displacement sensor, which is a diffuse reflection laser displacement sensor with a resolution of 0.001mm and a sampling frequency of 100Hz. A transparent acrylic protective plate is fixed below the laser displacement sensor.

7. A welding process for a magnetic separator media box, using the magnetic separator media box welding apparatus according to any one of claims 1 to 6, characterized in that: The method is as follows: S1: Medium box loading: Place the medium box to be welded on the medium box support platform and quickly lock the medium box to be welded in place; S2: Inputting dielectric box parameters: Input the geometric parameters of the dielectric box to be welded through the data input module. The geometric parameters include the number of rows, columns, row spacing, column spacing, diameter, and extension length of the metal rod. S3: Welding process generation: After obtaining the diameter of the metal rod, the path calculation module generates welding process parameters that correspond one-to-one with the diameter of the metal rod. The welding parameters include laser power, welding speed, defocusing amount, and pulse parameters. Then, the path calculation module automatically generates the welding process based on the dielectric cell parameters and welding parameters. The welding process includes the welding path and a process parameter table. S4: Welding Start: According to the welding process, the Y-axis shifting electric slide and the Z-axis slide of the two-axis electric slide are precisely aligned with the metal rod to be initially welded. Then, the X-axis slide of the two-axis electric slide drives the laser welding actuator to move towards the medium box to be welded, so that the laser welding actuator and the medium box to be welded are adjusted to the target focal length. Then, according to the process parameter table, the controller controls the first laser welding unit and the second laser welding unit to weld the two end faces of the medium box to be welded simultaneously. After the welding of one metal rod is completed, the laser welding actuator is shifted to the next metal rod according to the welding path. The Z-axis slide of the two-axis electric slide drives the laser welding actuator to change rows, and the Y-axis shifting electric slide drives the medium box carrying platform to change columns, so that the laser welding actuator is aligned with the next metal rod to be welded, and the welding of one row of metal rods is completed in sequence. S5: Path Compensation: After a row of metal rods is welded, the path compensation calculation module obtains the fluctuation value of the top surface of the medium box to be welded through the top surface fluctuation acquisition unit, and compensates the welding path according to the fluctuation value to generate a new welding path. The controller then welds other rows of metal rods according to the new welding path. S6: Welding and unloading. After welding is completed, the media box carrying platform drives the media box back to the initial position and removes the welded media box.

8. The welding process method for the magnetic separator media box according to claim 7, characterized in that, The welding path generation is as follows: After the controller obtains the medium box parameters, it generates the welding path based on the geometric parameters of the medium box and the path planning method. The path planning method is a double symmetrical welding sequence, as detailed below: Z-axis direction: Divide all metal bar rows in half from the middle, weld the middle row first, then weld the top and bottom rows of metal bars in sequence to complete the support system welding. Next, complete the welding of all rows of metal bars from top to bottom; when the number of metal bar rows is even, complete the welding of the middle two rows from top to bottom. Y-axis direction: When welding the support system, the metal bars in the same row are first welded to the metal bars in the middle column of that row, and then the welding is carried out alternately from the middle to both sides until all the metal bars in that row are welded.

9. The welding process method for the magnetic separator media box according to claim 7, characterized in that, The path compensation process is as follows: S51. Before welding, the displacement monitoring unit automatically measures the initial top surface height of the medium box to be welded; S52. During the welding process, the displacement monitoring unit measures the current top surface height in real time; S53. The path compensation calculation module automatically calculates the Z-axis offset of the laser welding actuator, that is, the initial top surface height minus the current top surface height; S54. After each row is welded, the controller adjusts the Z-axis coordinate of the laser welding actuator according to the current Z-axis offset, and then proceeds to weld the next row.

10. The welding process method for the magnetic separator media box according to claim 7, characterized in that, When the number of columns of the medium box to be welded is greater than 30, a Y-axis warping compensation step is also included: Before welding, the medium box carrying platform moves the medium box to be welded in the Y-axis direction, and the displacement monitoring unit scans the entire top surface of the medium box to obtain the initial height curve; after welding 5-10 rows of metal rods, the scan is repeated once to obtain the current height curve; the path compensation calculation module calculates the Y-coordinate offset and Z-coordinate offset based on the current height curve and the initial height curve; the controller controls the Z-axis slide and the Y-axis compensation slide of the two-axis electric slide to correct the offset.

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