An automatic welding device for iron accessories

Abstract

The application discloses an automatic iron accessory welding device, which comprises a welding table and a hoop, a pushing seat is installed on the welding table through a moving assembly, an inner full-arc soft plate is fixedly connected to the outside of the pushing seat, and an outer adhering structure is installed on the outside of the inner full-arc soft plate. When a worker welds the wing plate of the iron accessory hoop, the worker fixes the hoop at a specified position and pushes the hoop to bend to a specified curvature through the pushing seat. Meanwhile, the curvature formed by the hoop is detected by using the inner full-arc soft plate and a flexible resistance bending sensor when the hoop reaches the specified curvature. Only when the hoop reaches the specified curvature, the welding is started. If the hoop does not reach the specified curvature or the tolerance is out of the error range, it is determined that the workpiece is unqualified, and an alarm is given, so as to avoid the error tolerance phenomenon in the welding of the hoop and the wing plate and avoid the influence of the error tolerance on the strength of the whole workpiece.

Description

Technical Field

[0001] This invention relates to the field of welding technology for electrical components, and more specifically, to an automatic welding device for iron fittings. Background Technology

[0002] Power line accessories are indispensable components for power transmission and distribution lines and towers. As a core accessory, clamps are mainly used to tighten power poles and steel pipe poles, and work with flanges to install and fix crossarms, guy wires, insulators, and other components. Their processing quality directly determines the safety and stability of power line erection. Clamps are mostly semi-circular steel structures. Conventional processing requires welding flanges to the curved outer wall. Due to their unique curved structure, clamping, positioning, shape inspection, and simultaneous welding have always been challenging aspects of the industry's processing.

[0003] Currently, several automatic welding devices for iron accessories are available on the market, enabling mechanized clamping and welding of clamps and flanges, thus replacing traditional manual welding to some extent and reducing labor intensity and on-site operational risks. However, existing equipment still has several significant shortcomings in actual mass production: First, existing clamping fixtures mostly use rigid plates and blocks to limit the clamps at single points or both ends, only completing basic fixation and unable to detect the bending and forming accuracy of the clamps in real time. After bending, clamps are prone to problems such as curvature deviation, local deformation, and center offset. If unqualified workpieces directly enter the welding process, it will cause misalignment and poor fit of the flange welding, ultimately producing defective products and significantly increasing production costs. Second, conventional rigid clamping structures cannot adapt to clamps of different specifications and with minute dimensional tolerances. Therefore, an automatic welding device for iron accessories is proposed. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic welding device for iron accessories to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an automatic welding device for iron accessories, comprising a welding table and a clamp, wherein a pusher seat is mounted on the welding table via a moving component, an inner full-arc flexible plate is fixedly connected to the outside of the pusher seat, the clamp is attached to the outside of the inner full-arc flexible plate via a clamping structure, an outer fitting structure is mounted on the outside of the inner full-arc flexible plate, at least two welding robotic arms are mounted on the welding table, and a welding torch is mounted on the moving terminal of each welding robotic arm;

[0006] The outer bonding structure is used to cooperate with the inner full-arc flexible plate to detect the curvature of the other side of the clamp. Both the outer bonding structure and the inner full-arc flexible plate are equipped with magnetic attraction structures, and both the outer bonding structure and the inner full-arc flexible plate are equipped with detection structures.

[0007] The magnetic attraction structure is used to magnetically attach the outer bonding structure and the inner full-arc flexible plate to the outside of the clamp, thereby ensuring that the inner full-arc flexible plate and the outer bonding structure are accurately attached to the outside of the clamp.

[0008] Preferably, the outer bonding structure includes at least two elastic plates, which are fixedly connected to the outside of the inner full-arc flexible plate. An outer semi-arc flexible plate is fixedly connected to the side of the elastic plate away from the inner full-arc flexible plate. The outer semi-arc flexible plate is initially in a flat state. The outer semi-arc flexible plate is driven to bond to the outer wall surface of the inner full-arc flexible plate through a magnetic attraction structure to form a bonding curvature detection. The two elastic plates are spaced at least cm apart to form a space for placing and welding the wing plate.

[0009] Preferably, the magnetic attraction structure includes multiple electromagnet blocks, which are respectively located inside the inner full-arc flexible plate and the two elastic plates. The electromagnet blocks located inside the inner full-arc flexible plate and the outer semi-arc flexible plate are used to generate magnetism by energizing to attract the outer wall surface of the clamp, thereby causing the inner full-arc flexible plate and the outer semi-arc flexible plate to form a curvature with the same degree of bending as the clamp.

[0010] Preferably, the outer wall surface of the outer semi-circular flexible plate away from the elastic plate is connected to an elastic pull rope. One end of the elastic pull rope away from the outer semi-circular flexible plate is fixedly connected to the outside of the push seat. The elastic pull rope is used to prevent the outer semi-circular flexible plate from tilting upwards when it adsorbs the outer wall of the clamp. Both the inner full-circular flexible plate and the outer semi-circular flexible plate are covered with a heat-insulating and wear-resistant protective layer.

[0011] Preferably, the moving component includes a first drive motor, which is mounted on the bottom of the welding table. A linear screw is rotatably connected to the bottom of the welding table. The output shaft of the first drive motor is connected to one end of the linear screw via a coupling. A moving seat is threaded onto the external side of the linear screw. A pushing seat is fixedly connected to the outside of the moving seat. A first sliding groove is provided on the welding table, and the pushing seat is slidably connected to the inside of the first sliding groove.

[0012] Preferably, the clamping structure includes a bidirectional lead screw, which is rotatably connected to the bottom of the welding table. The external thread of the bidirectional lead screw is connected to two locking seats. The welding table has two adjustment slots on its exterior. The locking seats are slidably connected to the interior of the adjustment slots. A second drive motor is fixedly connected to the exterior of the welding table. The output shaft of the second drive motor is connected to one end of the bidirectional lead screw via a coupling. The locking seats have placement slots on their exteriors. Both sides of the clamp are locked into the placement slots of the two locking seats.

[0013] Preferably, the clamping structure further includes a lateral adjusting screw, which is threaded to the side wall of the placement groove, and a vertical adjusting screw is threaded to the top wall of the placement groove. Both the lateral adjusting screw and the vertical adjusting screw are rotatably connected to a pressing plate at one end inside the placement groove.

[0014] Preferably, the movable seat is provided with a second sliding groove, and a position adjusting screw is rotatably connected to one side of the inner wall of the second sliding groove. The external thread of the position adjusting screw is connected to a sliding seat, and an electromagnet positioning plate is connected to the sliding seat through a plug-in structure. The wing plate to be welded is placed on the electromagnet positioning plate. The sliding seat is used to adjust the sliding seat and the wing plate to a position close to the clamp for welding by driving the position adjusting screw.

[0015] Preferably, the plug-in structure includes at least two plug-in slots, which are formed inside the sliding seat. A plug-in rod is inserted into the plug-in slot. The top of the plug-in rod is fixedly connected to the bottom of the electromagnet positioning plate. A positioning groove is formed on the top of the electromagnet positioning plate. The shape of the positioning groove is the same as the bottom shape of the wing plate.

[0016] Preferably, multiple flexible resistance bending sensors are installed inside both the inner full-arc flexible plate and the outer semi-arc flexible plate.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] In this invention, when workers are welding the flange of the iron accessory clamp, they fix the clamp in a designated position and push it to bend to a specified curvature using a pusher. Simultaneously, once the clamp reaches the specified curvature, the curvature is detected using an inner full-arc flexible plate and a flexible resistance bending sensor. Welding only begins when the clamp reaches the specified curvature. If the curvature is not met or the tolerance is outside the error range, the workpiece is deemed unqualified and an alarm is triggered. This prevents erroneous tolerances in the welding of the clamp and flange, thus avoiding any impact on the overall strength of the workpiece. Attached Figure Description

[0019] Figure 1 This is one of the three-dimensional structural schematic diagrams of an embodiment of the present invention;

[0020] Figure 2 This is a second three-dimensional structural schematic diagram of an embodiment of the present invention;

[0021] Figure 3 This is the third three-dimensional structural schematic diagram of an embodiment of the present invention;

[0022] Figure 4 This is a schematic diagram of the outer semi-arc flexible plate and the inner full-arc flexible plate in an embodiment of the present invention;

[0023] Figure 5 This is a schematic diagram of the structure of multiple electromagnet blocks in an embodiment of the present invention;

[0024] Figure 6 This is a schematic diagram of the unfolded state of the outer semi-circular flexible plate in an embodiment of the present invention;

[0025] Figure 7 This is an embodiment of the present invention. Figure 1 A magnified structural diagram of area A in the diagram;

[0026] Figure 8 This is an embodiment of the present invention. Figure 2 A magnified structural diagram of region B in the diagram;

[0027] Figure 9 This is a cross-sectional view of the sliding seat in an embodiment of the present invention;

[0028] Figure 10 This is a schematic diagram of the structure of the heat-insulating and wear-resistant protective layer in an embodiment of the present invention;

[0029] In the picture:

[0030] 100. Welding table; 101. Push seat; 102. Clamp; 103. Inner full-arc flexible plate; 104. Welding robotic arm; 105. Flexible resistance bending sensor; 200. Electromagnetic block; 300. Elastic plate; 301. Outer semi-arc flexible plate; 400. Elastic pull rope; 500. First drive motor; 501. First sliding groove; 502. Direct-acting lead screw; 503. Moving seat; 600. Second drive motor; 601. Bidirectional lead screw; 602. Adjustment groove; 603. Snap-fit ​​seat; 700. Vertical adjustment screw; 701. Horizontal adjustment screw; 702. Extrusion plate; 800. Insertion groove; 801. Insertion rod; 900. Positioning groove; 901. Heat-insulating and wear-resistant protective layer; 902. Second sliding groove; 903. Position adjustment screw; 904. Sliding seat; 905. Electromagnetic positioning plate. Detailed Implementation

[0031] 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.

[0032] Example 1, such as Figures 1 to 10As shown, this embodiment provides an automatic welding device for iron accessories, including a welding table 100 and a clamp 102. A pusher seat 101 is installed on the welding table 100 via a moving component. An inner full-arc flexible plate 103 is fixedly connected to the outside of the pusher seat 101. The clamp 102 is attached to the outside of the inner full-arc flexible plate 103 via a clamping structure. An outer fitting structure is installed on the outside of the inner full-arc flexible plate 103. At least two welding robotic arms 104 are installed on the welding table 100. A welding torch is installed at the moving terminal of the welding robotic arm 104.

[0033] The outer bonding structure is used to cooperate with the inner full-arc flexible plate 103 to perform curvature detection on the other side of the clamp 102. Both the outer bonding structure and the inner full-arc flexible plate 103 have magnetic attraction structures installed inside, and both the outer bonding structure and the inner full-arc flexible plate 103 have detection structures installed inside.

[0034] The magnetic attraction structure is used to magnetically attach the outer bonding structure and the inner full-arc flexible plate 103 to the outside of the clamp 102, thereby ensuring that the inner full-arc flexible plate 103 and the outer bonding structure are accurately attached to the outside of the clamp 102.

[0035] Specifically, during use, the operator first places the clamp 102 on the clamping structure of the welding table 100 to complete the initial positioning. After the clamp 102 is positioned, the operator activates the moving component to drive the pusher 101 to move smoothly. The pusher 101 then drives the inner full-arc flexible plate 103, which is fixed on the outside, to gradually move towards the inner wall of the clamp 102 and fit tightly. Subsequently, the magnetic attraction structure inside the inner full-arc flexible plate 103 and the outer fitting structure is activated. After being energized, the magnetic attraction structure generates an electromagnetic attraction force, pulling the outer fitting. The entire structure bends and fits against the outer wall of the clamp 102, allowing the inner full-arc flexible plate 103 and the outer fitting structure to be completely attached to the workpiece surface from both the inner and outer sides of the clamp 102. During this process, the detection structure inside the inner and outer fitting structures is activated simultaneously to complete the real-time detection of the bending curvature and alignment status of the clamp 102 across the entire area. After the detection confirms that the curvature and position of the clamp 102 meet the processing standards, the welding robot arm 104 on the welding table 100 moves the end welding torch to the designated station to carry out the welding operation between the clamp 102 and the wing plate.

[0036] like Figures 1-3 As shown, the moving component includes a first drive motor 500, which is mounted on the bottom of the welding table 100. A linear screw 502 is rotatably connected to the bottom of the welding table 100. The output shaft of the first drive motor 500 is connected to one end of the linear screw 502 via a coupling. A moving seat 503 is threaded onto the outside of the linear screw 502. A push seat 101 is fixedly connected to the outside of the moving seat 503. A first sliding groove 501 is provided on the welding table 100, and the push seat 101 is slidably connected to the inside of the first sliding groove 501.

[0037] Specifically, during use, after the worker completes the initial positioning of the clamp 102 on the clamping structure, the worker starts the first drive motor 500 installed at the bottom of the welding table 100. After the first drive motor 500 is started, the output shaft of the first drive motor 500 will drive the linear lead screw 502 at the bottom of the welding table 100 to rotate continuously through the coupling. The rotating linear lead screw 502 drives the external moving seat 503 to make linear reciprocating motion through the thread transmission. The moving seat 503 simultaneously drives the push seat 101 fixed thereto to slide smoothly along the first sliding groove 501 on the welding table 100, thereby driving the inner full-arc soft plate 103 on the outer side of the push seat 101 to move closer to or away from the clamp 102, thus completing the clamping and loosening process of the clamp 102.

[0038] like Figures 1-8 As shown, the clamping structure includes a bidirectional lead screw 601, which is rotatably connected to the bottom of the welding table 100. Two locking seats 603 are threadedly connected to the outside of the bidirectional lead screw 601. Two adjusting grooves 602 are opened on the outside of the welding table 100. The locking seats 603 are slidably connected to the inside of the adjusting grooves 602. A second drive motor 600 is fixedly connected to the outside of the welding table 100. The output shaft of the second drive motor 600 is connected to one end of the bidirectional lead screw 601 through a coupling. The locking seats 603 have placement grooves on their outside. Both sides of the clamp 102 are locked into the placement grooves of the two locking seats 603.

[0039] Specifically, during use, the operator first starts the second drive motor 600, which is fixed on the outside of the welding table 100, according to the overall dimensions of the clamp 102 to be processed. When the second drive motor 600 is started, the output shaft of the second drive motor 600 will drive the bidirectional lead screw 601 at the bottom of the welding table 100 to rotate through the coupling. When the bidirectional lead screw 601 rotates, it will drive the two locking seats 603 to slide synchronously towards or away from each other along the corresponding adjustment grooves 602 on the welding table 100 through thread transmission, thereby adjusting the distance between the two locking seats 603. Then, the distance between the two locking seats 603 is adjusted to accommodate clamps 102 of different lengths. After the distance is adjusted, the operator inserts both ends of the clamp 102 into the placement grooves of the two locking seats 603 respectively, completing the initial clamping and positioning of the clamp 102.

[0040] like Figure 8 As shown, the clamping structure also includes a horizontal adjusting screw 701, which is threaded to the side wall of the placement groove. A vertical adjusting screw 700 is threaded to the top wall of the placement groove. Both the horizontal adjusting screw 701 and the vertical adjusting screw 700 are rotatably connected to a pressing plate 702 at one end inside the placement groove.

[0041] Specifically, during use, after the staff places both ends of the clamp 102 into the placement slot of the clamping seat for initial placement, they sequentially rotate the horizontal adjusting screw 701 threaded to the side wall of the placement slot and the vertical adjusting screw 700 on the top wall. As the two screws rotate, they push the end pressing plate 702 closer to the end of the clamp 102, clamping and limiting the clamp 102 from both horizontal and vertical directions. The structure of using the horizontal adjusting screw 701, the vertical adjusting screw 700, and the pressing plate 702 is used because it can lock and fix the clamp 102 from two dimensions, making up for the lack of stability of a single clamping position. It can adapt to the ends of the clamp 102 with different thicknesses and widths. At the same time, the clamping force can be controlled by the screw fine adjustment, which can ensure that the clamp 102 will not slip or deflect during inspection and welding, and can also avoid workpiece deformation or damage to the surface coating caused by hard extrusion.

[0042] Furthermore, by adjusting the horizontal and vertical positions, the specific lengths of the two ends of the clamp 102 can be limited, thus leaving a specified length at the middle position of the clamp 102. This ensures that the fixed lengths on both sides are the same when measuring the arc before welding the clamp 102, and prevents the phenomenon of one side being too long and the other side being too short.

[0043] like Figures 1-7 As shown, a second sliding groove 902 is provided on the movable seat 503. A position adjusting screw 903 is rotatably connected to one side of the inner wall of the second sliding groove 902. A sliding seat 904 is threadedly connected to the external side of the position adjusting screw 903. An electromagnet positioning plate 905 is connected to the sliding seat 904 through a plug-in structure. The wing plate to be welded is placed on the electromagnet positioning plate 905. The sliding seat 904 is used to adjust the sliding seat 904 and the wing plate to a position close to the clamp 102 for welding by the position adjusting screw 903.

[0044] Specifically, during use, the operator first places the wing plate to be welded stably on the electromagnet positioning plate 905 to complete the initial placement of the wing plate. Then, the position adjusting screw 903, which is installed on the inner wall of the second sliding groove 902, is rotated. The position adjusting screw 903 drives the sliding seat 904 to move linearly along the second sliding groove 902 via threaded transmission. The sliding seat 904 simultaneously drives the electromagnet positioning plate 905, which is connected by a plug-in structure, and the wing plate above it to move together, gradually approaching the already positioned clamp 102, until the wing plate and the outer wall of the clamp 102 are precisely fitted together, meeting the requirements of the welding station. After the wing plate is adjusted to the designated position, the electromagnet positioning plate 905 can be energized to achieve electromagnetic adsorption and fixation of the bottom of the wing plate, preventing the wing plate from tipping over during the welding process.

[0045] like Figure 9As shown, the plug-in structure includes at least two plug-in slots 800. The plug-in slots 800 are opened inside the sliding seat 904. A plug-in rod 801 is plugged into the plug-in slot 800. The top of the plug-in rod 801 is fixedly connected to the bottom of the electromagnet positioning plate 905. A positioning groove 900 is opened on the top of the electromagnet positioning plate 905. The shape of the positioning groove 900 is the same as the bottom shape of the wing plate.

[0046] Specifically, during use, when welding different types of wing plates, workers can replace different electromagnet positioning plates 905. Different positioning grooves 900 are opened on the outside of different electromagnet positioning plates 905 to adapt to the positioning and limiting welding work of different wing plates.

[0047] Furthermore, considering that different welding processes are used during welding, some iron accessories require high-temperature welding. Under high-temperature welding conditions, the electromagnet positioning plate 905 may experience insufficient magnetism due to the high temperature. Therefore, different positioning grooves 900 can be used to form mechanical limits, or clamping plates or other mechanical positioning methods can be used for clamping and limiting to avoid the effects of high-temperature welding.

[0048] Furthermore, during installation, the worker vertically inserts the plug rod 801 at the bottom of the electromagnet positioning plate 905 into the plug groove 800 inside the sliding seat 904, completing the assembly and fixation of the electromagnet positioning plate 905 and the sliding seat 904. Then, the wing plate to be welded is placed correspondingly inside the positioning groove 900 at the top of the electromagnet positioning plate 905. The shape of the positioning groove 900 limits the movement of the wing plate. When processing different models of wing plates, the current electromagnet can be removed by simply pulling the plug rod 801 upwards. The positioning plate 905 can be replaced with a matching positioning component for continued use. It adopts a plug-in structure with a plug-in slot 800 and a plug-in rod 801, and a positioning slot 900. The reason for this is that the plug-in connection is simple and quick to install and remove. The electromagnet positioning plate 905 can be replaced without the aid of tools. It can be quickly adapted to different specifications of wing plates, effectively improving the efficiency of equipment changeover. The matching positioning slot 900 can accurately limit the wing plate, preventing the wing plate from sliding or shifting during movement and welding, and ensuring the accuracy of the welding position.

[0049] like Figure 5 As shown, multiple flexible resistance bending sensors 105 are installed inside both the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301.

[0050] Specifically, during use, after the operator clamps the clamp 102 and positions it, the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 are tightly attached to the inner and outer arc surfaces of the clamp 102 under the action of the magnetic attraction structure, and bend synchronously with the clamp 102. Multiple flexible resistance bending sensors 105 installed inside the two flexible plates bend synchronously with the plates. The resistance value of the sensors changes linearly with the bending angle. The sensors transmit the analog resistance signal to the built-in PLC processor in real time. The PLC, combined with the preset program, completes the calculation... Based on calculation, comparison, and judgment, the actual bending curvature of the clamp 102 is detected, and the forming quality and alignment status are judged. The structure adopts multiple sets of flexible resistance bending sensors 105 built into the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301. The reason is that the flexible sensors can deform freely with the arc-shaped workpiece and fit without gaps. The arrangement of multiple measuring points can realize the full curvature detection of the clamp 102. Combined with PLC automatic calculation, it can replace manual visual inspection, and the detection accuracy and efficiency are higher. It can screen out unqualified workpieces with excessive curvature in advance and reduce the welding defect rate.

[0051] The calculation formula is as follows: The detection calculation is completed using the resistance-bending angle-radius of curvature conversion formula. The relationship between sensor resistance and bending angle is as follows: In the formula The real-time resistance value (Ω) of the sensor after bending. The initial reference resistance Ω of the sensor in a flat state. The inherent sensitivity coefficient Ω / ° of the flexible resistive bending sensor 105, The current bending angle of the sensor in °;

[0052] Arc geometric conversion formula: In the formula The measured radius of curvature of clamp 102 (in mm) is currently given. The fixed arc length (mm) between two adjacent detection points The angle of bending of the sensor at the corresponding measuring point is °;

[0053] Deviation Judgment Formula In the formula The deviation (in mm) between the measured radius of curvature and the standard radius of curvature is given. The standard radius of curvature (mm) is preset for the qualified clamp 102 of this model. Given the measured radius of curvature of clamp 102, when the PLC calculates... If the bending tolerance of clamp 102 is less than or equal to the system's set allowable tolerance value, the bending is deemed acceptable, and the welding process can proceed. If the workpiece exceeds the tolerance range, it is deemed unqualified, and the equipment will immediately alarm and suspend operation.

[0054] Furthermore, considering that the high temperature of welding iron accessories is still a factor in actual use, high-temperature welding may affect the sensor's detection. Therefore, during use, detection and welding can be separated into two areas: a detection area and a welding area. Detection is performed on the front side, and after the front side is completed, the clamp is moved to the welding area using the linear screw 502 for welding. If separation is required, components such as the locking seat 603 can also be set to be movable to achieve partitioned welding.

[0055] The technical solutions described in the above-described embodiments of this application have at least the following technical effects or advantages: Compared with the prior art, in this embodiment, when the worker is welding the wing plate of the iron accessory clamp 102, the clamp 102 is fixed in a designated position, and the clamp 102 is pushed and bent to a designated curvature by the push seat 101. At the same time, when the clamp 102 reaches the designated curvature, the curvature formed by the clamp 102 is detected by the inner full-arc soft plate 103 and the flexible resistance bending sensor 105. Welding only begins when the clamp 102 reaches the designated curvature. If the curvature is not reached or the tolerance is outside the error range, the workpiece is judged to be unqualified and an alarm is triggered, so as to avoid the welding of the clamp 102 and the wing plate with incorrect tolerance and avoid such incorrect tolerance affecting the strength of the entire workpiece.

[0056] Example 2: Considering that during use, the inner full-arc flexible plate 103 can only detect the curvature of the clamp 102 on one side, while the wing plate is generally installed on the other side of the clamp 102, if the curvature of the other side of the wing plate is different from that of the inner side, the inner full-arc flexible plate 103 on one side cannot detect it. To address the above technical problem, this application proposes the following technical solution to solve the above technical problem:

[0057] like Figure 4 As shown, the outer bonding structure includes at least two elastic plates 300. The elastic plates 300 are fixedly connected to the outside of the inner full-arc flexible plate 103. An outer semi-arc flexible plate 301 is fixedly connected to the side of the elastic plate 300 away from the inner full-arc flexible plate 103. The outer semi-arc flexible plate 301 is initially in a flat state. The outer semi-arc flexible plate 301 is driven to bond to the outer wall surface of the inner full-arc flexible plate 103 through a magnetic attraction structure to form a bonding curvature detection. The two elastic plates 300 are spaced at least 5 cm apart to form a space for placing and welding the wing plate.

[0058] Specifically, during use, after the operator clamps and positions the clamp 102 and attaches the inner full-arc flexible plate 103 to the inside of the clamp 102, the magnetic attraction structure is activated. This causes the outer semi-arc flexible plate 301, fixed on the elastic plate 300, to bend from its initial flat state towards the outside of the clamp 102 until it is tightly fitted against the outer wall of the clamp 102. Supported by the elastic plate 300, the outer semi-arc flexible plate 301 deforms synchronously with the outer arc surface of the clamp 102, and simultaneously collects curvature data from both the inner and outer sides of the clamp 102, along with the inner full-arc flexible plate 103. The at least 5cm gap between the two elastic plates 300 serves as a dedicated space for placing and welding the wing plate, without obstructing the wing plate installation or welding torch operation. The outer semi-circular flexible plate 301, combined with the outer bonding structure, solves the problem that relying solely on the inner full-circular flexible plate 103 for single-sided inspection cannot cover the outer side of the clamp 102 and makes it difficult to detect defects such as inconsistent curvature between the inner and outer sides. Through simultaneous inspection on both the inner and outer sides, the overall forming quality of the clamp 102 can be comprehensively determined, avoiding weak welding of the wing plate due to deviation in the outer curvature. At the same time, the adaptive deformation capability of the elastic plate 300 ensures that the outer semi-circular flexible plate 301 can tightly fit clamps 102 of different specifications, allowing the outer semi-circular flexible plate 301 to return to its original position after bonding through the elastic plate 300. The overall reserved welding space ensures the normal progress of subsequent wing plate installation and welding processes, improving the comprehensiveness of equipment inspection and process compatibility.

[0059] Furthermore, the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 are used in conjunction to achieve simultaneous detection of the inner and outer curvature of the clamp 102. On the one hand, since the clamp 102 is an arc-shaped component with a certain plate thickness, the material is affected by compression, tension and springback during the bending process, which can easily lead to defects such as inconsistent inner and outer curvature, local warping or cross-sectional distortion. Single-sided detection alone cannot fully identify such problems. However, simultaneous detection of the inner and outer sides can completely collect the contour data of the entire clamp 102, avoiding problems such as poor weld bonding of the flange and insufficient weld strength caused by deviation of the outer curvature, thus effectively improving the welding quality. On the other hand, through the inner and outer... By comparing the side curvature data, the actual bending radius and neutral layer position of the clamp 102 can be calculated, the bending stability can be judged, and the springback amount can be corrected online. At the same time, it can quickly screen for forming defects such as side bending and twisting, intercept unqualified workpieces in advance, and reduce the waste of welding materials and rework costs in subsequent processes. In addition, the wing plate positioning can be based on the outer arc curvature data collected by the outer semi-arc flexible plate 301, which can further improve the fitting accuracy between the wing plate and the clamp 102, ensure that the arc surface of the clamp 102 is uniformly fitted when it is installed on the utility pole, avoid uneven stress and fatigue cracking caused by local point contact, and comprehensively improve the assembly adaptability and use safety of the product.

[0060] The technical solutions in the above embodiments of this application have at least the following technical effects or advantages: Compared with Embodiment 1, in this embodiment, by using the inner full-arc soft plate 103 and the outer semi-arc soft plate 301, the inner and outer sides of the clamp 102 can be inspected simultaneously. On the one hand, the inspection accuracy is improved, and the situation of defective parts in welding is avoided. On the other hand, the actual bending radius and neutral layer position of the clamp 102 can be obtained by comparing the data of bidirectional curvature, so as to quickly screen unqualified workpieces and avoid the phenomenon of defective parts in welding.

[0061] In embodiment three, considering that during use, the inner full-arc flexible plate 103 can bend and fit against the clamp 102, while the outer semi-arc flexible plate 301 is not under external force and therefore cannot fully fit against the outer wall of the clamp 102, and that both the outer semi-arc flexible plate 301 and the inner full-arc flexible plate 103 may not fit properly, this application proposes the following technical solution to address the above technical problems:

[0062] like Figure 5 As shown, the magnetic attraction structure includes multiple electromagnet blocks 200, which are located inside the inner full-arc flexible plate 103 and the two elastic plates 300, respectively. The electromagnet blocks 200 located inside the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 are used to generate magnetism by energizing to attract the outer wall surface of the clamp 102, thereby causing the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 to form a curvature with the same degree of bending as the clamp 102.

[0063] Specifically, during use, the operator clamps the clamp 102 and positions it. After the inner full-arc flexible plate 103 is initially close to the inner wall of the clamp 102, the operator energizes the multiple electromagnet blocks 200 distributed inside the inner full-arc flexible plate 103 and the two elastic plates 300. The energized electromagnet blocks 200 generate a stable electromagnetic attraction. Utilizing the magnetic properties of the clamp 102 itself, the electromagnet blocks 200 simultaneously attract the clamp 102 from the inner and outer sides, thereby causing the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 to actively move towards the surface of the clamp 102 and bend synchronously with its contour. Finally, the two flexible plates form a complete contact with the clamp 102. With a uniform curvature, seamless and complete fit is achieved. By arranging multiple sets of electromagnet blocks 200 inside the inner full-arc flexible plate 103 and elastic plate 300, electromagnetic attraction can actively provide bonding force to the outer semi-arc flexible plate 301, solving the problem that it cannot independently adhere to the outer wall of the clamp 102 without external support. The multi-point arrangement of electromagnet blocks 200 can make the attraction force distribution more uniform, effectively improving the situation where the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 are not properly fitted in some areas, ensuring that the two flexible plates are tightly fitted to the clamp 102 throughout the entire process, providing an accurate data basis for subsequent curvature detection.

[0064] like Figure 6 As shown, considering that the outer semi-circular flexible plate 301 is initially in a flat state during use, it can pass through the bottom of the clamp 102 and move to the outside of the clamp 102 only in a flat state. However, when the outer semi-circular flexible plate 301 is magnetically adsorbed to the outside of the clamp 102, the adsorption may tilt, and it may not be able to accurately adsorb to the lower edge of the outer side wall of the clamp 102. Therefore, the following structure is set to solve the above technical problem: an elastic pull rope 400 is connected to the outer wall surface of the outer semi-circular flexible plate 301 away from the elastic plate 300. One end of the elastic pull rope 400 away from the outer semi-circular flexible plate 301 is fixedly connected to the outside of the push seat 101. The elastic pull rope 400 is used to prevent the outer semi-circular flexible plate 301 from tilting upward when adsorbing to the outer wall of the clamp 102. The inner full-arc flexible plate 103 and the outer semi-circular flexible plate 301 are both covered with a heat-insulating and wear-resistant protective layer 901.

[0065] Specifically, during use, the operator first keeps the outer semi-circular flexible plate 301 in its initial flat state, allowing it to smoothly pass through the bottom of the clamp 102 and move to the outer area of ​​the clamp 102. Then, the magnetic structure is energized, and the electromagnet block 200 generates magnetic force to attract and adhere the outer semi-circular flexible plate 301 to the outer wall of the clamp 102. During the bending and adsorption process of the outer semi-circular flexible plate 301, the elastic rope 400 connecting the outer semi-circular flexible plate 301 and the pusher seat 101 remains taut, providing downward tension and effectively preventing the outer semi-circular flexible plate 301 from tilting upwards, ensuring it precisely adheres to the lower edge of the outer wall of the clamp 102. The heat-insulating and wear-resistant protective layer 901 set on the outer side of the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301 can protect the flexible plate body during contact and operation. The reason for adding the elastic pull rope 400 and the heat-insulating and wear-resistant protective layer 901 is that it not only retains the requirement for the outer semi-arc flexible plate 301 to be laid flat and positioned, but also uses the limiting effect of the elastic pull rope 400 to correct the adsorption posture, completely solving the problem of the outer semi-arc flexible plate 301 tilting upward and the position of the bonding position shifting when magnetically attracted, ensuring that the flexible plate bonding position is accurate and the posture is upright. The heat-insulating and wear-resistant protective layer 901 can reduce friction loss, block the high temperature of welding, extend the service life of the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301, and reduce the impact of the high temperature of welding on internal inspection and use.

[0066] The technical solutions in the above-described embodiments of this application have at least the following technical effects or advantages: Compared with Embodiment 2, in this embodiment, by arranging electromagnet blocks 200 at multiple points inside the inner full-arc flexible plate 103 and the elastic plate 300, the uniform electromagnetic attraction generated after energization can actively drive the outer semi-arc flexible plate 301 to adhere to the outer wall of the clamp 102, effectively solving the problem that the outer semi-arc flexible plate 301 is difficult to adhere without external support. At the same time, the uniformly distributed magnetic force can avoid the defect of partial non-adhesion of the inner full-arc flexible plate 103 and the outer semi-arc flexible plate 301, so that the two flexible plates completely follow the contour of the clamp 102 and bend synchronously to achieve gapless adhesion, ensuring that the flexible resistance bending sensor 105 collects real and reliable curvature data, and improving the shape detection accuracy of the clamp 102.

[0067] Furthermore, after welding is completed, a set of follow-up flexible straightening rollers and multiple sets of elastic pressure rollers are installed on the welding table 100. After welding, the set of follow-up flexible straightening rollers and multiple sets of elastic pressure rollers can roll along the contour of the clamp to relieve welding stress and offset local thermal deformation. At the same time, the set of follow-up flexible straightening rollers and multiple sets of elastic pressure rollers are also equipped with micro array sensors. When the clamp rolls to release stress on the outer wall, the curvature after welding can be detected a second time to form a re-inspection effect.

[0068] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic welding device for iron accessories, comprising a welding table (100) and a clamp (102), characterized in that: The welding table (100) is equipped with a pusher seat (101) via a moving component. An inner full-arc flexible plate (103) is fixedly connected to the outside of the pusher seat (101). The clamp (102) is attached to the outside of the inner full-arc flexible plate (103) via a clamping structure. An outer fitting structure is installed on the outside of the inner full-arc flexible plate (103). At least two welding robotic arms (104) are installed on the welding table (100). The moving terminal of the welding robotic arm (104) is equipped with a welding torch. The outer bonding structure is used to cooperate with the inner full-arc soft plate (103) to perform curvature detection on the other side of the clamp (102). The outer bonding structure and the inner full-arc soft plate (103) are both equipped with magnetic suction structures. The outer bonding structure and the inner full-arc soft plate (103) are both equipped with detection structures. The magnetic attraction structure is used to drive the outer bonding structure and the inner full-arc flexible plate (103) to be magnetically bonded to the outside of the clamp (102), so that the inner full-arc flexible plate (103) and the outer bonding structure are accurately bonded to the outside of the clamp (102).

2. The automatic welding device for iron accessories according to claim 1, characterized in that: The outer bonding structure includes at least two elastic plates (300), which are fixedly connected to the outside of the inner full-arc flexible plate (103). An outer semi-arc flexible plate (301) is fixedly connected to the side of the elastic plate (300) away from the inner full-arc flexible plate (103). The outer semi-arc flexible plate (301) is initially flat. The outer semi-arc flexible plate (301) is driven to bond to the outer wall surface of the inner full-arc flexible plate (103) through a magnetic attraction structure to form a bonding curvature detection. The two elastic plates (300) are spaced at least 5 cm apart to form a space for placing and welding the wing plate.

3. The automatic welding device for iron accessories according to claim 2, characterized in that: The magnetic attraction structure includes multiple electromagnet blocks (200), which are located inside the inner full-arc flexible plate (103) and the two elastic plates (300), respectively. The electromagnet blocks (200) located inside the inner full-arc flexible plate (103) and the outer semi-arc flexible plate (301) are used to generate magnetism by energizing to attract the outer wall surface of the clamp (102), thereby causing the inner full-arc flexible plate (103) and the outer semi-arc flexible plate (301) to form a curvature with the same degree of bending as the clamp (102).

4. The automatic welding device for iron accessories according to claim 3, characterized in that: The outer semi-circular flexible plate (301) is connected to an elastic pull rope (400) on its outer wall surface away from the elastic plate (300). One end of the elastic pull rope (400) away from the outer semi-circular flexible plate (301) is fixedly connected to the outside of the push seat (101). The elastic pull rope (400) is used to prevent the outer semi-circular flexible plate (301) from tilting upwards when it adsorbs the outer wall of the clamp (102). The inner full-circular flexible plate (103) and the outer semi-circular flexible plate (301) are both covered with a heat-insulating and wear-resistant protective layer (901).

5. The automatic welding device for iron accessories according to claim 4, characterized in that: The moving component includes a first drive motor (500), which is mounted on the bottom of the welding table (100). A linear lead screw (502) is rotatably connected to the bottom of the welding table (100). The output shaft of the first drive motor (500) is connected to one end of the linear lead screw (502) via a coupling. A moving seat (503) is threaded onto the outside of the linear lead screw (502). A push seat (101) is fixedly connected to the outside of the moving seat (503). A first sliding groove (501) is provided on the welding table (100), and the push seat (101) is slidably connected to the inside of the first sliding groove (501).

6. The automatic welding device for iron accessories according to claim 1, characterized in that: The clamping structure includes a bidirectional lead screw (601), which is rotatably connected to the bottom of the welding table (100). The external thread of the bidirectional lead screw (601) is connected to two locking seats (603). The welding table (100) has two adjustment slots (602) on its exterior. The locking seats (603) are slidably connected to the interior of the adjustment slots (602). A second drive motor (600) is fixedly connected to the exterior of the welding table (100). The output shaft of the second drive motor (600) is connected to one end of the bidirectional lead screw (601) via a coupling. The locking seats (603) have placement slots on their exterior. Both sides of the clamp (102) are locked into the placement slots of the two locking seats (603).

7. The automatic welding device for iron accessories according to claim 1, characterized in that: The clamping structure also includes a lateral adjusting screw (701), which is threaded to the side wall of the placement groove. A vertical adjusting screw (700) is threaded to the top wall of the placement groove. Both the lateral adjusting screw (701) and the vertical adjusting screw (700) are rotatably connected to an extrusion plate (702) at one end inside the placement groove.

8. An automatic welding device for iron accessories according to claim 5, characterized in that: The movable seat (503) is provided with a second sliding groove (902). A position adjusting screw (903) is rotatably connected to one side of the inner wall of the second sliding groove (902). A sliding seat (904) is connected to the external thread of the position adjusting screw (903). An electromagnet positioning plate (905) is connected to the sliding seat (904) through a plug-in structure. The wing plate to be welded is placed on the electromagnet positioning plate (905). The sliding seat (904) is used to drive the sliding seat (904) and the wing plate to a position close to the clamp (102) for welding by the position adjusting screw (903).

9. An automatic welding device for iron accessories according to claim 8, characterized in that: The plug-in structure includes at least two plug-in slots (800), which are opened inside the sliding seat (904). A plug-in rod (801) is inserted into the plug-in slot (800). The top of the plug-in rod (801) is fixedly connected to the bottom of the electromagnet positioning plate (905). A positioning groove (900) is opened on the top of the electromagnet positioning plate (905). The shape of the positioning groove (900) is the same as the bottom shape of the wing plate.

10. An automatic welding device for iron accessories according to claim 1, characterized in that: Multiple flexible resistance bending sensors (105) are installed inside both the inner full-arc flexible plate (103) and the outer semi-arc flexible plate (301).

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