Automatic welding device and process for carbon block processing

Abstract

The application relates to the technical field of automatic welding, and discloses an automatic welding device and process for carbon block processing, and the automatic welding device for carbon block processing comprises a rack, a welding device and a conveying device, and further comprises a feeding and buffering mechanism and a rubber sleeve fitting mechanism, both of which are arranged on the rack; the feeding and buffering mechanism is used for buffering and lifting steel bars; the rubber sleeve fitting mechanism is used for driving the steel bars to move along a predetermined track, so that the steel bars are inserted into the inner cavity of a rubber pipe and cut off at a fixed length; a first material taking device is arranged between the feeding and buffering mechanism and the rubber sleeve fitting mechanism and is used for placing the buffered steel bars on the rubber sleeve fitting mechanism one by one; and a first material feeding device is arranged at the outlet end of the predetermined track of the rubber sleeve fitting mechanism and is used for providing rubber pipe raw materials to the rubber sleeve fitting mechanism; the application can realize smooth connection between processes, ensure the stability of the length and position of materials, improve the welding quality and product consistency, and realize the cooperative action between processes, so that the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of automated welding technology, specifically to an automated welding device and process for carbon block processing. Background Technology

[0002] Carbon blocks are a major component of aluminum electrolytic cells. They are usually laid at the bottom of the cell and come into direct contact with the high-temperature molten electrolyte and aluminum liquid. Together with the anode above, they form a complete electrical circuit. The performance of the cathode carbon blocks directly determines the service life and DC power consumption of the electrolytic cell.

[0003] During the production of aluminum electrolytic cell cathode carbon blocks, after the carbon blocks and steel bars have been assembled, cast, and cooled, cathode steel bars are welded to both sides of the steel bars to homogenize the internal pressure drop of the carbon blocks, improve the stability of the electrolytic cell operation, and enhance the overall mechanical connection and fixing strength. In addition, rubber tubes are fitted to the outside of the steel bars to slow down the chemical corrosion of the steel bars and extend their service life.

[0004] Currently, the feeding and welding of reinforcing bars during cathode carbon block welding usually rely on manual operation. The accuracy and stability of feeding and welding are difficult to guarantee, which can easily cause deviations in feeding size or welding position, seriously affecting welding quality and product consistency. In addition, the material flow efficiency is low, making it difficult to achieve continuous production. Furthermore, there is a lack of effective information transmission and processing capabilities between various processes, making it impossible to monitor changes in various parameters during the production process in real time. Summary of the Invention

[0005] This invention provides an automatic welding device and process for carbon block processing, which can achieve smooth connection between processes such as steel bar feeding, hose connection, cutting buffer, and welding material supply. It can also effectively buffer and schedule during material flow, enabling coordinated action between upstream and downstream processes, improving the accuracy and stability of feeding and welding, thereby improving the welding quality and production efficiency of carbon blocks, and solving the problems of low feeding and welding accuracy and stability and low material flow efficiency mentioned in the background art.

[0006] This invention provides the following technical solution:

[0007] An automatic welding device for carbon block processing includes a frame, welding equipment, and a conveying device. It further includes: a feeding and buffering mechanism and a sleeved-tube mechanism, both mounted on the frame. The feeding and buffering mechanism is used to buffer and lift reinforcing bars, and the sleeved-tube mechanism is used to drive the reinforcing bars along a predetermined trajectory, allowing them to pass through the inner cavity of a hose and be cut to a fixed length. A first material handling device is located between the feeding and buffering mechanism and the sleeved-tube mechanism, used to place the buffered reinforcing bars one by one onto the sleeved-tube mechanism. A first feeding device is located at the outlet end of the predetermined trajectory of the sleeved-tube mechanism, used to provide hose raw materials to the sleeved-tube mechanism. A feeding mechanism is also located on the frame. Below the rubber-coating mechanism, a buffer is used to catch the cut rubber-coated steel bars and to arrange the rubber-coated steel bars in an array; a second material-grabbing device is located above the feeding mechanism; a buffer device is located between the second material-grabbing device and the welding equipment, wherein the second material-grabbing device is used to grab the rubber-coated steel bars on the feeding mechanism and place them on the buffer device, and the buffer device is used to catch the rubber-coated steel bars and convey them to the welding equipment; the second feeding device is located between the conveying device and the second buffer device, and is used to grab the rubber-coated steel bars on the buffer device and place them on both sides of the carbon block on the conveying device.

[0008] As a preferred embodiment of the present invention, the feeding and buffering mechanism includes a linkage shaft, a lifting wheel, a chain, and a bracket. A bracket is mounted on the frame, the lifting wheel is rotatably connected to the bracket, the linkage shaft is connected to the shaft end of the upper lifting wheel, the chain is wound around the lifting wheel on the same side, the bracket is mounted on the side where the chains are close to each other, and a drive motor is mounted on the bracket. The output end of the drive motor is connected to the shaft end of one set of lifting wheels.

[0009] As a preferred embodiment of the present invention, the bottom of the bracket is provided with a plurality of arc-shaped grooves, the inner diameter of the grooves matching the outer diameter of the reinforcing bars, and the side of the bracket that is close to each other is open.

[0010] As a preferred embodiment of the present invention, the rubber sleeve mechanism includes a roller support, a feeding component, and a rubber sleeve section. The roller support has multiple frames and rollers, which are rotatably connected to the frames. The rollers on both sides are distributed crosswise on the frames. The feeding component consists of two conveying structures, and the distance between the two conveying structures matches the outer diameter of the reinforcing bar.

[0011] As a preferred embodiment of the present invention, the rubber sleeve includes a guide block, a positioning element, and a hose clamp. The guide block is disposed at the outlet end of the feeding element. The positioning element and the hose clamp are disposed on the side of the guide block away from the feeding element via a base plate. The hose clamp is slidably connected to the base plate, and the movement trajectory of the hose clamp matches the movement trajectory of the reinforcing bar. A cutter is disposed above the positioning element and the hose clamp, and the cutter reciprocates along the vertical direction of the reinforcing bar movement trajectory.

[0012] As a preferred embodiment of the present invention, the guide block, the positioning element and the hose clamp are all provided with guide grooves along the direction of the steel bar movement. The guide grooves are conical. One end of the hose material is connected to the first feeding device and the other end of the hose material is connected to the hose clamp.

[0013] As a preferred embodiment of the present invention, it further includes a redirection chute, which is installed on the base plate and located below the positioning member and the hose clamp. The redirection chute has a decreasing conical structure from top to bottom. The opening width at the top of the redirection chute is greater than the outer diameter of the rubber-coated steel bar and less than the length of the rubber-coated steel bar. The opening width at the bottom of the redirection chute matches the outer diameter of the rubber-coated steel bar.

[0014] As a preferred embodiment of the present invention, the feeding mechanism includes a buffer box and an elevator. The buffer box is located below the rubber sleeve mechanism, and the elevator is located on one side of the buffer box. The side of the buffer box away from the elevator is inclined. Multiple material picking troughs are evenly installed on the elevator. Each material picking trough includes a connecting part and a storage part. The storage part has an arc-shaped comb structure, and the inner diameter of the storage part matches the outer diameter of the rubber sleeve steel bar.

[0015] As a preferred embodiment of the present invention, the invention further includes an accumulating conveyor, a pusher, and a buffer conveyor. The accumulating conveyor is located on the side of the elevator away from the buffer box. A guide plate is provided between the accumulating conveyor and the elevator. The buffer conveyor is located on the side of the accumulating conveyor away from the elevator and is situated at the end of the accumulating conveyor's conveying action. The pusher is located on the side of the accumulating conveyor away from the buffer conveyor, and the pushing direction of the pusher matches the conveying direction of the top of the buffer conveyor. The top of the accumulating conveyor and the top of the buffer conveyor are connected by an inclined chute, and a soft baffle is provided at the outlet end of the chute.

[0016] An automated welding process for carbon block processing includes the following steps:

[0017] Step 1: After the system issues the production task, complete the preparation work for loading steel bars, carbon blocks and rubber hoses;

[0018] Step 2: Verify and compare the cathode carbon block specifications with the production task specifications. If the comparison is successful, transport the carbon block to the welding station.

[0019] Step 3: Check the quantity of steel bars, and after the quantity check meets the requirements, grab the steel bars and place them at the rubber-coating station;

[0020] Step 4: Insert the reinforcing bar into the inner cavity of the hose, and cut the hose and reinforcing bar simultaneously after reaching the preset length;

[0021] Step 5: Place the cut rubber-coated steel bars in the buffer station according to the preset order;

[0022] Step 6: Check the position and quantity of the rubber-coated steel bars at the buffer station, and then grab the rubber-coated steel bars to the welding supply station;

[0023] Step 7: Move the rubber-coated steel bar to the welding station and grab the rubber-coated steel bar to the welding station of the carbon block;

[0024] Step 8: Automatically weld the rubber-coated steel bars to the carbon blocks and inspect the weld quality;

[0025] Step 9: After welding is completed, the welded carbon block is transported to the next process.

[0026] Compared with the prior art, the present invention provides an automatic welding device and process for carbon block processing, which has the following beneficial effects:

[0027] 1. In this automatic welding device for carbon block processing, the first material handling device can place the steel bars on the feeding buffer mechanism onto the rubber sleeve mechanism, and the rubber sleeve mechanism can apply rubber to the steel bars. After a certain length, the rubber-sleeved steel bars are cut to ensure the accuracy and stability of subsequent welding, thereby improving the welding quality and product consistency.

[0028] 2. In this automatic welding device for carbon block processing, the cutting rubber-coated steel bars can be buffered by the feeding mechanism and conveyed to the welding point by the second feeding device, thereby ensuring the smooth connection between each process and enabling the upstream and downstream processes to work together, thereby improving production efficiency and meeting the needs of large-scale industrial continuous production.

[0029] The parts of this device not covered herein are the same as or can be implemented using existing technologies. This invention can achieve smooth connection between various processes, while ensuring the stability of material length and position, improving welding quality and product consistency, and enabling coordinated action between various processes to improve production efficiency. Attached Figure Description

[0030] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, the elements or parts are not necessarily drawn to scale.

[0031] Figure 1 This is a schematic diagram of the main structure of the present invention;

[0032] Figure 2 This is a side view of the structure of the present invention;

[0033] Figure 3 This is a top view of the structure of the present invention;

[0034] Figure 4 This is a schematic diagram of the main structure of the feeding buffer mechanism in this invention;

[0035] Figure 5 This is a side view of the feeding and buffering mechanism in this invention.

[0036] Figure 6 This is a partial side view of the first material handling device, the material feeding and buffering mechanism, and the rubber sleeve mechanism in this invention.

[0037] Figure 7 This is a partial front view schematic diagram of the rubber sleeve mechanism in this invention;

[0038] Figure 8 This is a partial front view schematic diagram of the feeding mechanism in this invention;

[0039] Figure 9 This is a partial top view of the feeding mechanism in this invention;

[0040] Figure 10 This is a process flow diagram of the present invention.

[0041] In the diagram: 1. Frame;

[0042] 2. Feeding and buffering mechanism; 201. Support; 202. Linkage shaft; 203. Lifting wheel; 204. Chain; 205. Bracket; 206. Drive motor;

[0043] 3. First material handling device; 4. First material feeding device;

[0044] 5. Rubber sleeve mechanism; 501. Support roller; 502. Feeding component; 503. Guide block; 504. Base plate; 505. Positioning component; 506. Hose clamp; 507. Cutting tool; 508. Diverting chute;

[0045] 6. Feeding mechanism; 601. Buffer box; 602. Elevator; 603. Receiving chute plate; 604. Guide plate; 605. Accumulation conveyor; 606. Pusher; 607. Baffle; 608. Buffer conveyor; 609. Chute;

[0046] 7. Second material handling device; 8. Buffer device; 9. Second material feeding device; 10. Welding equipment; 11. Conveying device. Detailed Implementation

[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0048] Example 1:

[0049] Reference Figures 1-9 An automatic welding device for carbon block processing includes a frame 1, welding equipment 10, and conveying device 11.

[0050] The frame 1 is usually made of carbon steel profiles and fixed on the ground to ensure that the whole machine does not shake during operation. The welding equipment 10 is the execution unit for welding operations between the cathode carbon block and the rubber-coated steel bar. It integrates functions such as a robotic arm, welding gun and vision recognition system, and can automatically complete welding trajectory planning and execution. The conveying device 11 is used for the station flow of the cathode carbon block to realize automatic conveying between stations such as feeding, welding and post-weld buffering. It usually adopts belt conveyor.

[0051] Reference Figure 2 , Figure 4 and Figure 5 The feeding buffer mechanism 2 and the rubber sleeve mechanism 5 are both set on the frame 1. The feeding buffer mechanism 2 is used to buffer and lift the steel bars, and the rubber sleeve mechanism 5 is used to drive the steel bars to move along a predetermined trajectory, so that the steel bars can be inserted into the inner cavity of the rubber tube and cut to a fixed length.

[0052] Rebar feeding is generally carried out using an AGV feeding system or manual feeding. The rebar is placed next to the feeding buffer mechanism 2, and then manually placed into different grooves of the bracket 205.

[0053] Reference Figure 4 and Figure 5The feeding and buffering mechanism 2 includes a linkage shaft 202, a lifting wheel 203, a chain 204, and a bracket 205. A bracket 201 is mounted on the frame 1. The lifting wheel 203 is rotatably connected to the bracket 201. The linkage shaft 202 is connected to the shaft end of the upper lifting wheel 203. The chain 204 is wound around the lifting wheel 203 on the same side. The bracket 205 is installed on the side of the chain 204 that is close to each other. A drive motor 206 is mounted on the bracket 201. The output end of the drive motor 206 is connected to the shaft end of one set of lifting wheels 203. Multiple arc-shaped grooves are evenly opened in the bottom of the bracket 205. The inner diameter of the groove matches the outer diameter of the steel bar. The side of the bracket 205 that is close to each other is open.

[0054] The lifting wheel 203 forms the pivot point for the chain 204. The linkage shaft 202 ensures the synchronous operation of the chains 204 on both sides, preventing the bracket 205 from tilting or jamming during lifting. The chain 204 is wound around the lifting wheel 203 on the same side to form a closed-loop transmission. The bracket 205 achieves paired load bearing on the left and right sides. When the drive motor 206 starts, the power is transmitted to the chain 204 through the lifting wheel 203, driving the bracket 205 to circulate up and down in the vertical direction, realizing the layer-by-layer lifting and feeding of the steel bars. The arc-shaped groove at the bottom of the bracket 205 is used to radially limit the steel bars, ensuring that the steel bars will not roll or shift after placement, achieving stable horizontal load bearing. The opening of the bracket 205 facilitates the first material grabbing device 3 to extend and grab the steel bars, avoiding interference of the bracket 205 structure with the material grabbing action. It also facilitates manual assistance in feeding or handling abnormalities from this side.

[0055] The bracket 205 is equipped with a visual recognition system at different heights on both sides. When the bracket 205 is in a low position, the system detects the storage status of the steel bars inside the bracket 205 and whether there are empty material positions. When the bracket is raised to a preset height, the raising stops so that the first material picking device 3 can grab the steel bars on the bracket 205.

[0056] Reference Figures 6-7 The rubber sleeve mechanism 5 includes a roller support 501, a feeding component 502, and a rubber sleeve part. The roller support 501 has multiple frames and rollers, which are rotatably connected to the frames. The rollers on both sides are distributed crosswise on the frames. The feeding component 502 consists of two conveying structures, and the distance between the two conveying structures matches the outer diameter of the steel bar.

[0057] The support rollers on both sides of the support roller component 501 are distributed in a cross pattern to form a V-shaped support structure, which allows the steel bars to fall naturally into the bottom of the V-shaped groove under the action of gravity, achieving automatic centering and stable bearing. The rotation of the support rollers provides axial driving force for the steel bars, allowing the steel bars to move smoothly towards the rubber sleeve station. The two conveying structures of the feeding component 502 form a clamping conveying channel, which provides auxiliary propulsion force during the steel bar threading process, ensuring that the front end of the steel bar accurately enters the guide block 503, while preventing the steel bar from deviating or rotating during the threading process.

[0058] Reference Figure 7 The rubber sleeve part includes a guide block 503, a positioning element 505, and a hose clamp 506. The guide block 503 is located at the outlet end of the feeder 502. The positioning element 505 and the hose clamp 506 are located on the side of the guide block 503 away from the feeder 502 via a base plate 504. The hose clamp 506 is slidably connected to the base plate 504, and the movement trajectory of the hose clamp 506 matches the movement trajectory of the reinforcing bar. A cutter 507 is provided above the positioning element 505 and the hose clamp 506. The cutter 507 moves back and forth in the direction perpendicular to the movement trajectory of the reinforcing bar. The guide block 503, the positioning element 505, and the hose clamp 506 are all provided with guide grooves in the direction of the reinforcing bar movement. The guide grooves are conical. One end of the rubber hose material is connected to the first feeding device 4, and the other end of the rubber hose material is connected to the hose clamp 506.

[0059] The tapered guide groove of the guide block 503 is used to precisely guide the front end of the reinforcing bar, so that the reinforcing bar can be smoothly aligned and inserted into the inner cavity of the hose in the positioning member 505 and the hose clamp 506. The positioning member 505 is used to mechanically limit the depth of the reinforcing bar inserted into the hose to ensure the consistency of the sleeve length. The hose clamp 506 can move along the axial direction of the reinforcing bar under the drive of a servo motor or other drive structure, pulling the hose out from the first feeding device 4 and sleeve it onto the surface of the reinforcing bar. The cutter 507 moves back and forth in the direction perpendicular to the moving trajectory of the reinforcing bar. When the reinforcing bar is sleeved into the hose to the set length, the cutter 507 falls (the cutter 507 is generally driven by electric mechanical transmission or hydraulic drive), simultaneously cutting the hose and the reinforcing bar to form a fixed-length sleeved reinforcing bar.

[0060] The guide block 503, positioning element 505, and hose clamp 506 form a continuous guide channel with tapered guide grooves along the direction of rebar movement. This allows the front end of the rebar to have a large tolerance range when entering the guide groove. As the rebar goes deeper, the groove gradually tightens, ultimately achieving precise centering and reducing the requirements for the straightness and front end shape of the rebar. In addition, a visual recognition system needs to be installed above the positioning element 505 and hose clamp 506 to determine the rubber coating status of the rebar, so as to make timely adjustments or repairs.

[0061] It also includes a redirection chute 508, which is installed on the base plate 504 and is located below the positioning component 505 and the hose clamp 506. The redirection chute 508 has a tapered structure that decreases from top to bottom. The opening width at the top of the redirection chute 508 is greater than the outer diameter of the rubber-coated steel bar and less than the length of the rubber-coated steel bar. The opening width at the bottom of the redirection chute 508 matches the outer diameter of the rubber-coated steel bar.

[0062] The redirecting chute 508 is used to receive the cut rubber-coated steel bars and change their falling direction. It adopts a decreasing conical structure from top to bottom to ensure that the rubber-coated steel bars fall into the redirecting chute 508 after rotating 90 degrees horizontally after being cut, avoiding chaotic posture during falling. This allows the rubber-coated steel bars to be discharged orderly through the bottom of the redirecting chute 508, which facilitates the accurate receiving of the material by the buffer box 601 below. This achieves automatic redirection and posture adjustment of the material after cutting without manual intervention.

[0063] Reference Figure 2 and Figure 6 The first material handling device 3 is located between the feeding buffer mechanism 2 and the sleeve mechanism 5, and is used to place the buffered steel bars one by one onto the sleeve mechanism 5; the first material supply device 4 is located at the outlet end of the predetermined trajectory of the sleeve mechanism 5, and is used to supply the hose material to the sleeve mechanism 5.

[0064] The first material handling device 3 is a flexible gripper structure capable of moving in multiple directions (typically with functions such as lifting, translation, gripping, and releasing) to realize the transfer of steel bars on the bracket 205 to the support roller 501. The position is set to minimize the gripping stroke, and the action rhythm matches the sleeve mechanism 5 to ensure synchronous connection of upstream and downstream processes. Reliable gripping of steel bars of different specifications can be achieved through pneumatic flexible grippers, avoiding surface damage to the steel bars caused by rigid clamping. The first material feeding device 4 typically adopts a buffer feeding method for coiled rubber hose raw materials. The starting end of the rubber hose raw material is connected to the rubber hose clamp 506, and the rubber hose clamp 506 pulls out the rubber hose when moving to achieve active feeding. At the same time, the first material feeding device 4 can also adjust the tension of the rubber hose to facilitate the sleeve connection between the rubber hose and the steel bar.

[0065] Reference Figure 1 , Figure 8 and Figure 9 The feeding mechanism 6 is located below the sleeve mechanism 5 and is used to buffer the cut sleeved steel bars and arrange them in an array. The feeding mechanism 6 includes a buffer box 601 and an elevator 602. The buffer box 601 is located below the sleeve mechanism 5 and the elevator 602 is located on one side of the buffer box 601. The side of the buffer box 601 away from the elevator 602 is inclined. Multiple material picking troughs 603 are evenly installed on the elevator 602. Each material picking trough 603 includes a connecting part and a storage part. The storage part has an arc-shaped comb structure and the inner diameter of the storage part matches the outer diameter of the sleeved steel bar.

[0066] The falling rubber-coated steel bars enter the buffer box 601 under the action of gravity, and the inclined surface of the buffer box brings the rubber-coated steel bars close to the elevator 602, preventing material from accumulating in dead corners at the bottom of the box.

[0067] The arc-shaped comb-shaped material trough plate 603 allows it to pass through the corresponding gaps between the comb teeth at the bottom of the buffer box 601 during the upward process, separating and lifting the bottom steel bars one by one, avoiding multiple bars from sticking together, and realizing the orderly extraction of materials. In addition, a vision recognition system can be added to both sides of the elevator 602 to monitor the lifting status of the rubber-coated steel bars, so that maintenance can be carried out in a timely manner in case of failure or other situations.

[0068] Reference Figures 8-9 It also includes an accumulating conveyor 605, a pusher 606, and a buffer conveyor 608. The accumulating conveyor 605 is located on the side of the elevator 602 away from the buffer box 601. A guide plate 604 is provided between the accumulating conveyor 605 and the elevator 602. The buffer conveyor 608 is located on the side of the accumulating conveyor 605 away from the elevator 602, and the buffer conveyor 608 is located at the end of the conveying of the accumulating conveyor 605. The pusher 606 is located on the side of the accumulating conveyor 605 away from the buffer conveyor 608, and the pushing direction of the pusher 606 matches the conveying direction of the top of the buffer conveyor 608. The top of the accumulating conveyor 605 and the top of the buffer conveyor 608 are connected by an inclined chute 609. A soft baffle 607 is provided at the outlet end of the chute 609.

[0069] The accumulating conveyor 605, the pusher 606, and the buffer conveyor 608 form a multi-stage conveying and buffering system. Both the accumulating conveyor 605 and the buffer conveyor 608 adopt belt conveyor structures. The pusher 606 can be driven by an electric actuator or a cylinder. A vision recognition system is added at the accumulating conveyor 605, the output end, and the buffer conveyor 608 to determine the conveying and buffering status of the rubber-coated steel bars. After being lifted, the rubber-coated steel bars fall onto the accumulating conveyor 605 under the action of the guide plate 604 until the rubber-coated steel bars are conveyed to the end of the accumulating conveyor 605 (the end is usually equipped with a blocking structure so that the conveying of the rubber-coated steel bars stops when they reach the end). Then, the pusher 606 is controlled to push the rubber-coated steel bars to the buffer conveyor 608. This not only prevents the rubber-coated steel bars from accumulating on the accumulating conveyor 605, but also reduces the ineffective work of the pusher 606, realizing the step-by-step transfer and buffering of the rubber-coated steel bars. This allows the rubber coating process and the welding process to operate independently with optimal cycle time.

[0070] The chute 609 is used to ensure the smooth transport of the rubber-coated steel bars from the accumulating conveyor 605 to the buffer conveyor 608. The soft baffle 607 is used to provide flexible buffering for the sliding rubber-coated steel bars, avoiding rigid collisions that could damage the surface of the rubber-coated steel bars or break the rubber tubes. At the same time, it slows down the falling speed, allowing the rubber-coated steel bars to fall smoothly into the designated position of the buffer conveyor 608. The buffer conveyor 608 is equipped with a groove that matches the rubber-coated steel bars, so that the rubber-coated steel bars are limited by the groove when falling.

[0071] Reference Figures 1-3 The second material handling device 7 is located above the material feeding mechanism 6; the buffer device 8 is located between the second material handling device 7 and the welding equipment 10. The second material handling device 7 is used to grab the rubber-coated steel bars on the material feeding mechanism 6 and put them onto the buffer device 8. The buffer device 8 is used to buffer the rubber-coated steel bars and transport them to the welding equipment 10.

[0072] The second material handling device 7 is used to grab and transfer the arrayed rubber-coated steel bars on the buffer conveyor 608 in batches to the buffer device 8. The second material handling device 7 can adopt a flexible gripping mechanism with multiple claws and multiple moving directions, and cooperate with a vision recognition system to achieve precise gripping of the rubber-coated steel bars. The buffer device 8 can adopt a linear track drive method and is equipped with a rubber-coated steel bar support structure. The support structure is used to limit and support the rubber-coated steel bars. After the rubber-coated steel bars are grabbed, they can be transferred to the welding station by the linear track. At the same time, it has a buffering effect on the rubber-coated steel bars, so that the welding process does not have to wait for the real-time output of the rubber coating process, and achieves flexible matching of production cycle.

[0073] The second feeding device 9 is located between the conveying device 11 and the second buffer device 8. It is used to grab the rubber-coated steel bars on the buffer device 8 and place the rubber-coated steel bars on both sides of the carbon block on the conveying device 11.

[0074] The second feeding device 9 also uses a combination of a gripping mechanism and a vision recognition system. Through a combination of rotation, lifting, and translation, it accurately grips the rubber-coated steel bars on the buffer device 8 and places them into the predetermined welding areas on both sides of the carbon block on the conveying device 11. Finally, the rubber-coated steel bars can be welded to both sides of the carbon block by the welding equipment 10.

[0075] Example 2:

[0076] Similar to Example 1, an automated welding process for carbon block processing is proposed based on Example 1, including the following steps:

[0077] Step 1: After the system issues the production task, complete the preparation work for loading steel bars, carbon blocks and rubber hoses;

[0078] The operator sends a production task containing process parameters such as cathode carbon block specifications, hose connection length, and welding position to the intelligent information processing system through the production management system. Then, three material preparations are completed: the fixed-length steel bars are sequentially filled into the bracket 205 of the material feeding buffer mechanism 2; the cathode carbon blocks are placed on the conveying device 11 by AGV or forklift; and the coiled hose raw material is loaded into the first feeding device 4, while the starting end of the hose raw material is connected to the hose clamp 506, laying the material foundation for subsequent fully automated operation.

[0079] Step 2: Verify and compare the cathode carbon block specifications with the production task specifications. If the comparison is successful, transport the carbon block to the welding station.

[0080] After the system starts, the visual recognition system collects the specification information of the cathode carbon blocks in the current batch and compares it with the production task specification issued by the upper system to ensure that the carbon blocks currently being fed are completely consistent with the production task requirements, preventing batch welding defects due to mixing or incorrect feeding. After successful comparison, the conveying device 11 transports the cathode carbon blocks to the welding station and stops, waiting for subsequent welding operations. If the comparison fails, the system immediately alarms and reminds relevant personnel to verify and process the error, thus achieving production error prevention.

[0081] Step 3: Check the quantity of steel bars, and after the quantity check meets the requirements, grab the steel bars and place them at the rubber-coating station;

[0082] The visual recognition system at the end of the bracket 205 of the feeding buffer mechanism 2 detects the number of steel bars in the bracket 205. After confirming that there is no shortage of materials and the material picking conditions are met, the electrical control system controls the drive motor 206 to move and lift the corresponding bracket 205 to the picking position of the first picking device 3. After the visual recognition system is triggered, the drive motor 206 stops, the first picking device 3 descends and grabs a single steel bar, then rises and moves above the rubber sleeve mechanism 5, and releases the steel bar into the V-shaped groove formed by the roller component 501, completing the transfer of the steel bar to the rubber sleeve position.

[0083] Step 4: Insert the reinforcing bar into the inner cavity of the hose, and cut the hose and reinforcing bar simultaneously after reaching the preset length;

[0084] After the visual recognition system at the end of the support roller 501 detects the signal of the reinforcing bar entering, the control system starts the rotation of the support roller to convey the reinforcing bar towards the feeding component 502. At the same time, the hose clamp 506 slides along the base plate 504 under the drive of the servo motor, pulling the hose out of the first feeding device 4 and moving it towards the feeding component 502, so that the reinforcing bar passes through the hose. When the length of the reinforcing bar inserted into the hose reaches the system set value, the detection signal is triggered, the control system stops the rotation of the support roller and the action of the feeding component 502, the hose clamp 506 retracts to the initial picking position, and the cutter 507 falls to simultaneously cut the hose and the reinforcing bar, forming a rubber-insulated reinforcing bar with the hose outside and the length of the set value.

[0085] Step 5: Place the cut rubber-coated steel bars in the buffer station according to the preset order;

[0086] After being cut, the rubber-coated steel bars fall freely into the redirecting chute 508 through the discharge port, and after rotating 90 degrees, they fall into the buffer box 601. After the visual recognition system at the top of the buffer box 601 is triggered, the elevator 602 is activated. The material picking trough plate 603 uses the complementary characteristics of the comb-shaped structure and the comb-shaped structure at the bottom of the buffer box 601 to lift the rubber-coated steel bars from the buffer box 601 and raise them to the top discharge port. After passing through the guide plate 604, they fall into the accumulation conveyor 605 and are conveyed to the discharge end. After the visual recognition system is triggered, the pusher 606 pushes the steel bars to the buffer station of the buffer conveyor 608, filling each station in sequence, realizing the array arrangement and orderly buffering of the rubber-coated steel bars.

[0087] Step 6: Check the position and quantity of the rubber-coated steel bars at the buffer station, and then grab the rubber-coated steel bars to the welding supply station;

[0088] The second material handling device 7 descends to the material handling height and moves horizontally above the buffer conveyor 608. It uses a vision recognition system to acquire and process images of the rubber-coated steel bars at the buffer station, identifying the specific location coordinates and quantity of materials at each station. Based on the vision recognition results, it adjusts its position, and the pneumatic material handling grippers adjust their spacing and align with the rubber-coated steel bars at each station. The grippers then perform a batch grabbing action and move above the buffer device 8, releasing the rubber-coated steel bars into the V-shaped cross-section buffer position of the buffer device 8, thus completing the material transfer to the welding feeding station.

[0089] Step 7: Move the rubber-coated steel bar to the welding station and grab the rubber-coated steel bar to the welding station of the carbon block;

[0090] After the buffer device 8 detects that the material filling is complete, it moves along the linear slide rail to the material picking station of the second feeding device 9. The second feeding device 9 descends to the material picking height, adjusts the spacing and grabs the rubber-coated steel bar. After the grab is completed, it is lifted and the steel bar is transferred to the carbon block welding station. At the same time, the vision recognition system accurately places the rubber-coated steel bar in the predetermined welding area on both sides of the cathode carbon block, completing the final material placement before welding.

[0091] Step 8: Automatically weld the rubber-coated steel bars to the carbon blocks and inspect the weld quality;

[0092] The front-end vision recognition system of welding equipment 10 acquires images of the current welding area, identifies the actual relative position of the rubber-coated steel bar and the cathode carbon block, and compares it with the preset welding position. If there is a deviation, the intelligent information processing system calculates the compensation amount and sends it to the robotic arm controller. The robotic arm performs welding operations according to the compensated trajectory. The welding wire is fed out by the welding wire assembly through the welding gun. During the welding process, the vision recognition system monitors the weld formation in real time. After the welding is completed, the weld quality is inspected again, and the inspection results are fed back to the intelligent information processing system for storage, realizing closed-loop control of welding quality.

[0093] Step 9: After welding is completed, the welded carbon block is transported to the next process.

[0094] After the welding operation is completed, the information is fed back to the electrical control system, and the conveyor 11 is restarted to transport the welded carbon block from the welding station to the post-weld buffer station. Then the system waits for the AGV to unload, completing a full production cycle.

[0095] In addition, during all the above processes, the intelligent information processing system continuously collects data such as the operation status of various vision recognition systems and actuators, and displays it in real time on the screen. Operators can monitor the production progress, adjust process parameters, and view quality reports through the terminal, realizing digital management of the entire production process.

[0096] Components not described in detail in this article are existing technologies.

[0097] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic welding device for carbon block processing, comprising a frame (1), welding equipment (10), and a conveying device (11), characterized in that, Also includes: The feeding buffer mechanism (2) and the rubber sleeve mechanism (5) are both set on the frame (1). The feeding buffer mechanism (2) is used to buffer and lift the steel bars, and the rubber sleeve mechanism (5) is used to drive the steel bars to move along a predetermined trajectory so that the steel bars can be inserted into the inner cavity of the rubber tube and cut off at a fixed length. The first material handling device (3) is located between the feeding buffer mechanism (2) and the rubber sleeve mechanism (5) and is used to place the buffered steel bars one by one onto the rubber sleeve mechanism (5); The first feeding device (4) is located at the outlet end of the predetermined trajectory of the sleeve mechanism (5) and is used to supply the sleeve mechanism (5) with the raw material of the hose. The feeding mechanism (6) is located below the sleeve mechanism (5) and is used to buffer the cut sleeved steel bars and to arrange the sleeved steel bars in an array. The second material handling device (7) is disposed above the feeding mechanism (6); A buffer device (8) is disposed between the second material handling device (7) and the welding equipment (10). The second material handling device (7) is used to grab the rubber-coated steel bar on the feeding mechanism (6) and place it onto the buffer device (8). The buffer device (8) is used to buffer the rubber-coated steel bar and transport the rubber-coated steel bar to the welding equipment (10). The second feeding device (9) is located between the conveying device (11) and the second buffer device (8) for gripping the rubber-coated steel bars on the buffer device (8) and placing the rubber-coated steel bars on both sides of the carbon block on the conveying device (11).

2. The automatic welding device for carbon block processing according to claim 1, characterized in that, The feeding buffer mechanism (2) includes a linkage shaft (202), a lifting wheel (203), a chain (204), and a bracket (205). A bracket (201) is installed on the frame (1). The lifting wheel (203) is rotatably connected to the bracket (201). The linkage shaft (202) is connected to the shaft end of the upper lifting wheel (203). The chain (204) is wound around the lifting wheel (203) on the same side. The bracket (205) is installed on the side where the chains (204) are close to each other. A drive motor (206) is installed on the bracket (201). The output end of the drive motor (206) is connected to the shaft end of one of the lifting wheels (203).

3. The automatic welding device for carbon block processing according to claim 2, characterized in that, The bottom of the bracket (205) is evenly provided with multiple arc-shaped grooves, the inner diameter of the grooves is matched with the outer diameter of the reinforcing bars, and the side of the bracket (205) that is close to each other is open.

4. The automatic welding device for carbon block processing according to claim 1, characterized in that, The rubber sleeve mechanism (5) includes a roller component (501), a feeding component (502), and a rubber sleeve part. The roller component (501) has multiple frames and rollers. The rollers are rotatably connected to the frames, and the rollers on both sides are distributed crosswise on the frames. The feeding component (502) consists of two conveying structures, and the distance between the two conveying structures matches the outer diameter of the reinforcing bar.

5. The automatic welding device for carbon block processing according to claim 4, characterized in that, The rubber sleeve includes a guide block (503), a positioning element (505), and a hose clamp (506). The guide block (503) is located at the outlet end of the feeding element (502). The positioning element (505) and the hose clamp (506) are located on the side of the guide block (503) away from the feeding element (502) via a base plate (504). The hose clamp (506) is slidably connected to the base plate (504), and the movement trajectory of the hose clamp (506) matches the movement trajectory of the reinforcing bar. A cutter (507) is provided above the positioning element (505) and the hose clamp (506). The cutter (507) moves back and forth along the vertical direction of the reinforcing bar movement trajectory.

6. The automatic welding device for carbon block processing according to claim 5, characterized in that, The guide block (503), positioning element (505) and hose clamp (506) are all provided with guide grooves along the direction of the steel bar movement. The guide grooves are conical. One end of the hose material is connected to the first feeding device (4), and the other end of the hose material is connected to the hose clamp (506).

7. An automatic welding device for carbon block processing according to claim 5, characterized in that, It also includes a redirection chute (508), which is installed on the base plate (504) and located below the positioning member (505) and the hose clamp (506). The redirection chute (508) has a decreasing conical structure from top to bottom. The opening width at the top of the redirection chute (508) is greater than the outer diameter of the rubber-coated steel bar and less than the length of the rubber-coated steel bar. The opening width at the bottom of the redirection chute (508) matches the outer diameter of the rubber-coated steel bar.

8. The automatic welding device for carbon block processing according to claim 1, characterized in that, The feeding mechanism (6) includes a buffer box (601) and a hoist (602). The buffer box (601) is located below the rubber sleeve mechanism (5). The hoist (602) is located on one side of the buffer box (601). The side of the buffer box (601) away from the hoist (602) is inclined. Multiple material picking troughs (603) are evenly installed on the hoist (602). The material picking trough (603) includes a connecting part and a storage part. The storage part is an arc-shaped comb structure, and the inner diameter of the storage part matches the outer diameter of the rubber sleeve steel bar.

9. An automatic welding device for carbon block processing according to claim 8, characterized in that, It also includes an accumulation conveyor (605), a pusher (606), and a buffer conveyor (608). The accumulation conveyor (605) is located on the side of the elevator (602) away from the buffer box (601). A guide plate (604) is provided between the accumulation conveyor (605) and the elevator (602). The buffer conveyor (608) is located on the side of the accumulation conveyor (605) away from the elevator (602), and the buffer conveyor (608) is located at the end of the conveying of the accumulation conveyor (605). The pusher (606) is located on the side of the accumulating conveyor (605) away from the buffer conveyor (608), and the pushing direction of the pusher (606) matches the conveying direction of the top of the buffer conveyor (608). The top of the accumulating conveyor (605) and the top of the buffer conveyor (608) are connected by an inclined chute (609), and a soft baffle (607) is provided at the outlet end of the chute (609).

10. An automatic welding process for carbon block processing, employing the automatic welding device for carbon block processing as described in any one of claims 1-9, comprising the following steps: Step 1: After the system issues the production task, complete the preparation work for loading steel bars, carbon blocks and rubber hoses; Step 2: Verify and compare the cathode carbon block specifications with the production task specifications. If the comparison is successful, transport the carbon block to the welding station. Step 3: Check the quantity of steel bars, and after the quantity check meets the requirements, grab the steel bars and place them at the rubber-coating station; Step 4: Insert the reinforcing bar into the inner cavity of the hose, and cut the hose and reinforcing bar simultaneously after reaching the preset length; Step 5: Place the cut rubber-coated steel bars in the buffer station according to the preset order; Step 6: Check the position and quantity of the rubber-coated steel bars at the buffer station, and then grab the rubber-coated steel bars to the welding supply station; Step 7: Move the rubber-coated steel bar to the welding station and grab the rubber-coated steel bar to the welding station of the carbon block; Step 8: Automatically weld the rubber-coated steel bars to the carbon blocks and inspect the weld quality; Step 9: After welding is completed, the welded carbon block is transported to the next process.

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