Automatic plate welding system and automatic plate welding method

Abstract

An automatic plate welding system comprises a rack, a conveying device, a first anti-deformation device, a second anti-deformation device, a supporting device and a welding device. The rack comprises a first layer and a second layer. The first layer comprises a first station and a second station. The second layer is provided with a first positioning surface and a second positioning surface. The conveying device is used for conveying a first plate and a second plate to the first station and the second station. The first anti-deformation device comprises a first lifting part and a first anti-deformation part. The first lifting part drives the first anti-deformation part to rise. The first anti-deformation part is used for positioning the first plate on the first positioning surface. The second anti-deformation device comprises a second lifting part and a second anti-deformation part. The second lifting part drives the second anti-deformation part to rise. The second anti-deformation part is used for positioning the second plate on the second positioning surface. The supporting device comprises a third lifting part and a pad. The third lifting part drives the pad to be attached to the first plate and the second plate. The welding device is used for welding a first welding edge and a second welding edge.

Description

Technical Field

[0001] This invention relates to the field of plate welding technology, and in particular to an automatic plate welding system and an automatic plate welding method. Background Technology

[0002] Rotary drilling rigs are important engineering machinery. The mast side plate assembly is made of two or more steel plates spliced ​​together, and the welding quality directly affects the performance and service life of the workpiece.

[0003] Traditional mast side plate welding operations largely rely on manual labor. A crane lifts the workpieces (first and second steel plates) and places them onto a tooling platform. Multiple positioning blocks are located on one side of the platform. A robotic arm pushes the first and second steel plates against these positioning blocks, simultaneously using a centering line for positioning. Finally, a manual welding torch is used to weld the first and second steel plates together. However, traditional mast side plate welding has the following drawbacks: First, the mast's steel plates are long and thin, making hoisting difficult.

[0004] Secondly, manual welding is inefficient, time-consuming, and prone to deformation during the welding process, affecting the precision and strength of the workpiece.

[0005] Third, manual welding is difficult to guarantee in terms of precision and positioning, and is prone to problems such as uneven welds, porosity, and slag inclusions.

[0006] Fourth, manual welding is labor-intensive and requires high skill levels from operators. Summary of the Invention

[0007] In view of this, the present invention provides an automatic plate welding system that can automatically position and weld, achieving full automation without human intervention.

[0008] An automatic plate welding system, comprising: The frame includes a first shelf and a second shelf. The first shelf includes a first workstation, an intermediate workstation and a second workstation arranged sequentially along a first direction. The second shelf is disposed above the first shelf and has a first positioning surface facing the first workstation and a second positioning surface facing the second workstation. A conveying device is connected to the first shelf, and the conveying device is used to convey the first board and the second board to the first workstation and the second workstation respectively along the first direction; A first anti-deformation device is provided at the first work station. The first anti-deformation device includes a first lifting part and a first anti-deformation part. The first lifting part is used to drive the first anti-deformation part to rise so that the first anti-deformation part lifts the first plate and disengages it from the conveying device. The first anti-deformation part is used to position the first plate on the first positioning surface. The second anti-deformation device is provided at the second work station. The second anti-deformation device includes a second lifting part and a second anti-deformation part. The second lifting part is used to drive the second anti-deformation part to rise so that the second anti-deformation part lifts the second plate and disengages it from the conveying device. The second anti-deformation part is used to position the second plate on the second positioning surface. A support device is provided at the intermediate work station. The support device includes a third lifting part and a pad block. The pad block is provided with a forming groove. The third lifting part is used to drive the pad block to fit against the edges of the first plate and the second plate. The first welding edge of the first plate and the second welding edge of the second plate are correspondingly provided with the forming groove. A welding device for welding the first welding edge to the second welding edge together.

[0009] Optionally, the automatic plate welding system further includes a first photoelectric switch, a second photoelectric switch, a laser positioning device, and a controller. The first photoelectric switch, the second photoelectric switch, and the laser positioning device are installed on the second shelf. The first photoelectric switch is correspondingly set at the junction of the first workstation and the intermediate workstation, the second photoelectric switch is correspondingly set at the junction of the second workstation and the intermediate workstation, and the laser positioning device is correspondingly set at the intermediate workstation. The controller is electrically connected to the first photoelectric switch, the second photoelectric switch, the laser positioning device, the conveying device, the first anti-deformation device, the second anti-deformation device, and the support device. The first photoelectric switch and the second photoelectric switch are used to detect the positions of the first plate and the second plate. The laser positioning device is used to detect the distance between the first welding edge and the second welding edge. The controller controls the start / stop and conveying speed of the conveying device according to the signals fed back by the first photoelectric switch and the second photoelectric switch, and controls the conveying device to adjust the distance between the first welding edge and the second welding edge according to the signals fed back by the laser positioning device.

[0010] Optionally, the first lifting part includes a first lifting drive mechanism and a first platform, the first lifting drive mechanism is connected to the first platform, and the first anti-deformation part is connected to the first platform; The second lifting part includes a second lifting drive mechanism and a second platform. The second lifting drive mechanism is connected to the second platform, and the second anti-deformation part is connected to the second platform.

[0011] Optionally, the first platform is divided into at least two first placement areas, the at least two first placement areas are arranged at intervals along the first direction, each first placement area extends along the second direction, the second direction and the first direction have an angle, and each first placement area is used to arrange the first anti-deformation part. The first anti-deformation part includes a plurality of first drivers and a first telescopic shaft connected to each of the first drivers. Each of the first drivers is used to drive the first telescopic shaft to position the first plate on the first positioning surface. The second platform is divided into at least two second placement areas, which are arranged at intervals along the first direction. Each second placement area extends along the second direction and is used to arrange the second anti-deformation part. The second anti-deformation part includes a plurality of second drivers and a second telescopic shaft connected to each of the second drivers. Each of the second drivers is used to drive the second telescopic shaft to position the second plate on the second positioning surface.

[0012] Optionally, the automatic plate welding system further includes a first magnetic suction device, which is disposed on the first platform and is used to generate magnetic attraction to fix the first plate onto multiple first telescopic shafts; or the first magnetic suction device is disposed on the second shelf and is used to generate magnetic attraction on the first positioning surface to fix the first plate. The automatic plate welding system further includes a second magnetic suction device, which is disposed on the second platform and is used to generate magnetic attraction to fix the second plate onto multiple second telescopic shafts. Alternatively, the second magnetic suction device can be disposed on the second shelf and is used to generate magnetic attraction on the second positioning surface to fix the second plate.

[0013] Optionally, the pad includes multiple support surfaces, each of which is used to support the first plate and the second plate, and each of the support surfaces is provided with the forming groove.

[0014] Optionally, the pad is provided with a cooling channel, and the support device further includes a cooling circulator connected to the cooling channel. The cooling circulator delivers coolant in the cooling channel to reduce the temperature of the pad.

[0015] Optionally, the first station is provided with a first positioning element, which is arranged along the first direction; the automatic plate welding system further includes a first positioning device, which is used to push the first plate so that the side of the first plate abuts against the first positioning element. The second workstation is provided with a second positioning component, which is arranged along the first direction; the automatic plate welding system also includes a second positioning device, which is used to push the second plate so that the side of the second plate abuts against the second positioning component; The first workstation is provided with a third positioning component, which is arranged along the first direction and is located on opposite sides of the first workstation, respectively. The automatic plate welding system also includes a third positioning device, which is used to push the third plate so that the side of the third plate abuts against the third positioning component. The second workstation is provided with a fourth positioning component, which is arranged along the first direction and is located on opposite sides of the second workstation, respectively. The automatic plate welding system also includes a fourth positioning device, which is used to push the fourth plate so that the side of the fourth plate abuts against the fourth positioning component.

[0016] This application also relates to an automatic welding method for sheet metal, the automatic welding method for sheet metal utilizing the aforementioned automatic welding system for sheet metal, the automatic welding method for sheet metal comprising: The conveying device is controlled to convey the second sheet material to the second workstation and the first sheet material to the first workstation; Control the first lifting part to drive the first anti-deformation part to rise, so that the first anti-deformation part lifts the first plate and separates it from the conveying device, and control the first anti-deformation part to position the first plate on the first positioning surface. Control the second lifting part to drive the second anti-deformation part to rise, so that the second anti-deformation part lifts the second plate away from the conveying device, and control the second anti-deformation part to position the second plate on the second positioning surface; The third lifting part is controlled to drive the pad block to fit against the edges of the first plate and the second plate, and the first welding edge and the second welding edge are arranged to correspond with the forming groove. The welding device is controlled to weld the first welding edge and the second welding edge together.

[0017] Optionally, the method for adjusting the distance between the first welding edge and the second welding edge includes: The control device conveys the second plate material sequentially through the first photoelectric switch and the second photoelectric switch; Before the second plate passes the first photoelectric switch, the conveying device is controlled to convey the second plate at a first speed; When the second plate passes the first photoelectric switch, the conveying device is controlled to convey the second plate at a second speed, wherein the first speed is greater than the second speed; When the second plate passes the second photoelectric switch, the conveying device is controlled to convey the second plate at a third speed, where the second speed is greater than the third speed. When the laser positioning device detects that the position of the second plate is at the first position, the conveying device is controlled to stop conveying the second plate. Based on the deviation between the second plate and the second position, the conveying device is controlled to reverse and convey the second plate to the second position; The conveying device is controlled to stop conveying the first plate when it reaches the first photoelectric switch. Based on the distance between the second welding edge of the second plate and the first welding edge of the first plate detected by the laser positioning device, the conveying device is controlled to convey the first plate to a third position so that the first welding edge and the second welding edge are correspondingly set with the forming groove.

[0018] The automatic plate welding system of this invention can automatically transport a first plate and a second plate, and uses a first anti-deformation device to position the first plate on a first positioning surface and a second anti-deformation device to position the second plate on a second positioning surface. This effectively prevents reverse deformation during welding of the first and second plates, ensuring the flatness of the first and second plates after welding. Furthermore, the automatic plate welding system of this application can automatically position and weld, achieving full automation without manual intervention. In addition, because the first and second welding edges are provided with corresponding forming grooves, double-sided forming can be achieved in a single welding operation, resulting in stable and reliable welding quality without the need for post-weld flipping and re-welding. The third lifting part of this application can drive the pad block to fit tightly against the lower surfaces of the first and second plates, ensuring the quality of the weld formation. Attached Figure Description

[0019] Figure 1 This is a side view of the automatic plate welding system of this application.

[0020] Figure 2 yes Figure 1 The diagram shown is a right-side view of the automatic plate welding system.

[0021] Figure 3 yes Figure 1 The diagram shows a top view of the automatic plate welding system.

[0022] Figure 4 This is a top-view schematic diagram of the first platform of this application.

[0023] Figure 5 This is a top view of the second platform of this application.

[0024] Figure 6 This is a cross-sectional structural diagram of the pad block of this application.

[0025] Figure 7 This is a schematic diagram of the pad extending along the second direction in this application. Detailed Implementation

[0026] The following specific embodiments illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification.

[0027] In the following description, reference is made to the accompanying drawings, which illustrate several embodiments of the present application. It should be understood that other embodiments may also be used, and changes in mechanical composition, structure, electrical and operational aspects may be made without departing from the spirit and scope of the present application. The following detailed description should not be considered limiting, and the terminology used herein is for describing particular embodiments only and is not intended to limit the present application.

[0028] Although the terms first, second, etc., are used in some instances to describe various elements herein, these elements should not be limited by these terms. These terms are only used to distinguish one element from another.

[0029] Furthermore, as used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It should be further understood that the terms “comprising,” “including,” indicate the presence of a feature, step, operation, element, component, item, kind, and / or group, but do not exclude the presence, occurrence, or addition of one or more other features, steps, operations, elements, components, items, kinds, and / or groups. The terms “or” and “and / or” as used herein are interpreted as inclusive, or mean any one or any combination thereof. Thus, “A, B, or C” or “A, B, and / or C” means “any one of: A; B; C; A and B; A and C; B and C; A, B, and C.” Exceptions to this definition arise only when combinations of elements, functions, steps, or operations are inherently mutually exclusive in some way.

[0030] Figure 1 This is a side view of the automatic plate welding system of this application. Figure 2 yes Figure 1 The diagram shown is a right-side view of the automatic plate welding system. Figure 3 yes Figure 1The diagram shown is a top view of the automatic plate welding system. Figure 1 , Figure 2 and Figure 3 As shown, the automatic plate welding system includes: The frame 11 includes a first shelf 111 and a second shelf 112. The first shelf 111 includes a first workstation, an intermediate workstation and a second workstation arranged sequentially along a first direction X. The second shelf 112 is arranged above the first shelf 111 and has a first positioning surface facing the first workstation and a second positioning surface facing the second workstation. Conveying device 12 is connected to the first shelf 111. Conveying device 12 is used to convey the first board and the second board to the first workstation and the second workstation respectively along the first direction X. The first anti-deformation device 13 is set at the first work station. The first anti-deformation device 13 includes a first lifting part 131 and a first anti-deformation part 132. The first lifting part 131 is used to drive the first anti-deformation part 132 to rise, so that the first anti-deformation part 132 lifts the first plate and disengages it from the conveying device 12. The first anti-deformation part 132 is used to position the first plate on the first positioning surface. The second anti-deformation device 14 is set at the second work station. The second anti-deformation device 14 includes a second lifting part 141 and a second anti-deformation part 142. The second lifting part 141 is used to drive the second anti-deformation part 142 to rise so that the second anti-deformation part 142 lifts the second plate and removes it from the conveying device 12. The second anti-deformation part 142 is used to position the second plate on the second positioning surface. Support device 15 is set at the middle work station. Support device 15 includes a third lifting part 151 and a pad 152. The pad 152 is provided with a forming groove 101. The third lifting part 151 is used to drive the pad 152 to fit against the edges of the first plate and the second plate. The first welding edge of the first plate and the second welding edge of the second plate are correspondingly provided with the forming groove 101. A welding device is used to weld the first welding edge and the second welding edge together. In this embodiment, the first plate and the second plate are, for example, the mast side plates of a rotary drilling rig. This application splices multiple plates together to form a mast, but is not limited thereto.

[0031] The automatic plate welding system of this application can automatically transport the first plate and the second plate, and use the first anti-deformation device 13 to position the first plate on the first positioning surface and the second anti-deformation device 14 to position the second plate on the second positioning surface. This effectively prevents reverse deformation during welding of the first and second plates, ensuring the flatness of the first and second plates after welding. Furthermore, the automatic plate welding system of this application can automatically position and weld, achieving full automation without manual intervention. In addition, since the first and second welding edges are corresponding to the forming grooves 101, double-sided forming can be achieved in a single welding operation, resulting in stable and reliable welding quality without the need for post-weld flipping and re-welding. The third lifting part 151 of this application can drive the pad 152 to fit tightly against the lower surfaces of the first and second plates, ensuring the quality of the weld formation.

[0032] The automatic plate welding system of this application is suitable for welding long and thin mast side plates (the side plates are formed by welding together at least one first plate and at least one second plate), which can ensure welding quality and flatness, improve the overall performance of the mast and the construction safety of rotary drilling rigs.

[0033] Optionally, the first positioning surface is formed by combining multiple first positioning blocks arranged in a matrix; the second positioning surface is formed by combining multiple second positioning blocks arranged in a matrix, but is not limited thereto.

[0034] Optionally, the conveying device 12 includes multiple conveying rollers and a conveying drive mechanism. Each conveying roller is arranged along the second direction Y, and the multiple conveying rollers are arranged sequentially at intervals along the first direction X. At least two conveying rollers are arranged at the first workstation, and at least two conveying rollers are arranged at the second workstation. The conveying drive mechanism is used to drive each conveying roller to rotate in both directions, thereby conveying the first and second sheet materials. In this embodiment, the conveying drive mechanism includes a servo motor module and multiple transmission chains. The servo motor module drives each conveying roller to rotate through each transmission chain.

[0035] Alternatively, the welding device may be, for example, a welding robot, but is not limited thereto.

[0036] Optionally, such as Figure 3As shown, the automatic plate welding system also includes a first photoelectric switch 16, a second photoelectric switch 17, a laser positioning device 18, and a controller (not shown). The first photoelectric switch 16, the second photoelectric switch 17, and the laser positioning device 18 are installed on the second shelf 112. The first photoelectric switch 16 is correspondingly set at the junction of the first workstation and the intermediate workstation, the second photoelectric switch 17 is correspondingly set at the junction of the second workstation and the intermediate workstation, and the laser positioning device 18 is correspondingly set at the intermediate workstation. The controller is electrically connected to the first photoelectric switch 16, the second photoelectric switch 17, the laser positioning device 18, the conveying device 12, the first anti-deformation device 13, the second anti-deformation device 14, and the support device 15. The first photoelectric switch 16 and the second photoelectric switch 17 are used to detect the positions of the first plate and the second plate. The laser positioning device 18 is used to detect the distance between the first welding edge and the second welding edge. The controller controls the start and stop of the conveying device 12 and the conveying speed according to the signals fed back by the first photoelectric switch 16 and the second photoelectric switch 17, and controls the conveying device 12 to adjust the distance between the first welding edge and the second welding edge according to the signals fed back by the laser positioning device 18.

[0037] The automatic plate welding system of this embodiment uses a first photoelectric switch 16, a second photoelectric switch 17, and a laser positioning device 18 to detect the positions of the first and second plates in real time. The controller adjusts the transmission device 12 based on the feedback signal, thereby adjusting the distance between the first and second welding edges to ensure that the first and second plates are in the optimal welding position, which is beneficial to improving welding quality. Moreover, the controller can control the coordinated operation of each device in a closed loop based on the feedback signal, achieving high-precision and high-reliability automatic positioning with a positioning accuracy of less than 0.5 mm.

[0038] The process by which the conveying device 12 of this application conveys the second plate to the second workstation is as follows: Before the second plate passes the first photoelectric switch 16, the conveying device 12 conveys the second plate at a first speed; when the second plate passes the first photoelectric switch 16, the conveying device 12 conveys the second plate at a second speed, where the first speed is greater than the second speed; when the second plate passes the second photoelectric switch 17, the conveying device 12 conveys the second plate at a third speed, where the second speed is greater than the third speed. When the laser positioning device 18 detects that the position of the second plate is at the first position, the conveying device 12 stops conveying the second plate; based on the deviation between the second plate and the second position, the conveying device 12 reverses and conveys the second plate to the second position. When the second plate is at the second station, the second welding edge of the second plate is at the intermediate station.

[0039] The process by which the conveying device 12 of this application conveys the first plate to the first workstation is as follows: When the second plate passes the second photoelectric switch 17, the conveying device 12 starts conveying the first plate. Conveying stops when the first plate reaches the first photoelectric switch 16. Based on the distance between the second welding edge of the second plate and the first welding edge of the first plate detected by the laser positioning device 18, the controller controls the conveying device 12 to convey the first plate to a third position, so that the first welding edge and the second welding edge are correspondingly positioned with the forming groove 101. When the first plate is in the first station, the first welding edge of the first plate is in the middle station.

[0040] Optionally, such as Figure 3 As shown, the laser positioning device 18 includes a first laser and a second laser, which are arranged opposite to each other along the second direction Y. The first laser and the second laser are respectively arranged at both ends of the forming groove 101. In this embodiment, the angle between the second direction Y and the first direction X is 90°, but it is not limited to this.

[0041] Optionally, the laser positioning device 18 includes a first movable frame and a first position adjuster. The first movable frame is movably connected to the second shelf 112 along the second direction Y. The first laser is connected to the first movable frame. The first position adjuster is connected between the first movable frame and the second shelf 112. The first position adjuster is used to adjust the position of the first laser along the second direction Y.

[0042] Optionally, the laser positioning device 18 includes a second movable frame and a second position adjuster. The second movable frame is movably connected to the second shelf 112 along the second direction Y. The second laser is connected to the second movable frame. The second position adjuster is connected between the second movable frame and the second shelf 112. The second position adjuster is used to adjust the position of the second laser along the second direction Y.

[0043] Optionally, the controller may be, for example, a PLC controller, but is not limited thereto.

[0044] Optionally, such as Figure 1 and Figure 2 As shown, the first lifting part 131 includes a first lifting drive mechanism 1311 and a first platform 1312. The first lifting drive mechanism 1311 is connected to the first platform 1312, and the first anti-deformation part 132 is connected to the first platform 1312. In this embodiment, the first lifting drive mechanism 1311 is, for example, a cylinder mechanism, a hydraulic cylinder mechanism, or a servo motor module, but is not limited thereto; the first platform 1312 is parallel to the first direction X and the second direction Y, and the first platform 1312 is used to provide a support platform for the first anti-deformation part 132.

[0045] Optionally, the second lifting part 141 includes a second lifting drive mechanism 1411 and a second platform 1412. The second lifting drive mechanism 1411 is connected to the second platform 1412, and the second anti-deformation part 142 is connected to the second platform 1412. In this embodiment, the second lifting drive mechanism 1411 is, for example, a cylinder mechanism, a hydraulic cylinder mechanism, or a servo motor module, but is not limited thereto; the second platform 1412 is parallel to the first direction X and the second direction Y, and the second platform 1412 is used to provide a support platform for the second anti-deformation part 142.

[0046] Optionally, Figure 4 This is a top view of the first platform of this application, as shown below. Figure 4 As shown, the first platform 1312 is divided into at least two first placement areas, which are arranged at intervals along the first direction X. Each first placement area extends along the second direction Y, and there is an angle (e.g., 90°) between the second direction Y and the first direction X. Each first placement area is used to arrange the first anti-deformation part 132. The first anti-deformation section 132 includes a plurality of first actuators 1321 and a first telescopic shaft 1322 connected to each of the first actuators 1321. Each first actuator 1321 is used to drive the first telescopic shaft 1322 to position the first plate on the first positioning surface. In this embodiment, each first actuator 1321 is, for example, a hydraulic cylinder or a pneumatic cylinder, but is not limited thereto.

[0047] In this embodiment, each first placement area is provided with a plurality of first drivers 1321 arranged sequentially along the second direction Y. Each first driver 1321 in each row of the first placement area can drive the first telescopic shaft 1322 to position the first plate. This design is beneficial to reduce the reverse deformation of the first plate during welding.

[0048] Optionally, Figure 5 This is a top view of the second platform of this application, as shown below. Figure 5 As shown, the second platform 1412 is divided into at least two second placement areas, which are arranged at intervals along the first direction X. Each second placement area extends along the second direction Y, and each second placement area is used to arrange the second anti-deformation part 142. The second anti-deformation section 142 includes a plurality of second actuators 1421 and a second telescopic shaft 1422 connected to each second actuator 1421. Each second actuator 1421 is used to drive the second telescopic shaft 1422 to position the second plate on the second positioning surface. In this embodiment, each second actuator 1421 is, for example, a hydraulic cylinder or a pneumatic cylinder, but is not limited thereto.

[0049] In this embodiment, each of the second placement areas is provided with a plurality of second drivers 1421 arranged sequentially along the second direction Y. Each of the second drivers 1421 in each row of the second placement area can drive the second telescopic shaft 1422 to position the second plate. This design is beneficial to reduce the reverse deformation of the second plate during welding and improve the flatness of the first plate and the second plate.

[0050] Optionally, such as Figure 4 As shown, the automatic plate welding system also includes a first magnetic attraction device 19, which is disposed on the first platform 1312. The first magnetic attraction device 19 is used to generate magnetic attraction force to fix the first plate onto multiple first telescopic shafts 1322.

[0051] In this embodiment, the first magnetic attraction device 19 can generate magnetic force to attract and fix the first plate to the end face of each first telescopic shaft 1322, and each first driver 1321 can drive the first telescopic shaft 1322 to position the first plate on the first positioning surface. The first magnetic attraction device 19 and the first anti-deformation part 132 cooperate to pre-apply reverse deformation to the first plate to counteract welding deformation. The amount of reverse deformation is adjustable (the deformation is adjustable by controlling the magnitude of the magnetic force) to ensure the flatness of the first plate after welding.

[0052] Optionally, such as Figure 4 As shown, the first magnetic attraction device 19 includes a plurality of first electromagnetic blocks 191 and a first power supply unit (not shown) electrically connected to each of the first electromagnetic blocks 191. The plurality of first electromagnetic blocks 191 are arranged sequentially at intervals along the second direction Y, and the plurality of first electromagnetic blocks 191 are arranged alternately with the plurality of first drivers 1321 in each first placement area.

[0053] In other embodiments, a first magnetic attraction device 19 is disposed on a second shelf 112, and the first magnetic attraction device 19 is used to generate a magnetic attraction force on the first positioning surface to attract and fix the first plate.

[0054] Optionally, such as Figure 5 As shown, the automatic plate welding system also includes a second magnetic suction device 21, which is mounted on the second platform 1412. The second magnetic suction device 21 is used to generate magnetic attraction to fix the second plate onto multiple second telescopic shafts 1422.

[0055] In this embodiment, the second magnetic attraction device 21 can generate magnetic force to attract and fix the second plate to the end face of each second telescopic shaft 1422, and each second driver 1421 can drive the second telescopic shaft 1422 to position the second plate on the second positioning surface. The second magnetic attraction device 21 and the second anti-deformation part 142 cooperate to pre-apply reverse deformation to the second plate to counteract welding deformation. The amount of reverse deformation is adjustable (the deformation is adjustable by controlling the magnitude of the magnetic force) to ensure the flatness of the second plate after welding.

[0056] Optionally, such as Figure 4 As shown, the second magnetic attraction device 21 includes a plurality of second electromagnetic blocks 211 and a second power supply unit (not shown) electrically connected to each of the second electromagnetic blocks 211. The plurality of second electromagnetic blocks 211 are arranged sequentially at intervals along the second direction Y, and the plurality of second electromagnetic blocks 211 are arranged alternately with the plurality of second drivers 1421 in each second placement area.

[0057] In other embodiments, a second magnetic attraction device 21 is disposed on the second shelf 112, and the second magnetic attraction device 21 is used to generate a magnetic attraction force on the second positioning surface to attract and fix the second plate.

[0058] Optionally, Figure 6 This is a cross-sectional structural diagram of the pad block of this application, as shown below. Figure 1 and Figure 6 As shown, the pad 152 includes multiple support surfaces 1521, each of which supports the first plate and the second plate. Each support surface 1521 is provided with a forming groove 101. In this embodiment, the pad 152 is arranged along the second direction Y, that is, the length direction of the pad 152 is parallel to the second direction Y, and the length direction of the forming groove 101 is parallel to the second direction Y. The forming groove 101 divides the support surface 1521 into a left support surface and a right support surface. The left support surface is used to support the first plate, and the right support surface is used to support the second plate.

[0059] The pad 152 in this embodiment has multiple support surfaces 1521 for supporting the plates. After any support surface 1521 is worn, the pad 152 can be rotated at a certain angle, and the unworn support surface 1521 can be used to support the first plate and the second plate, which can improve the service life of the pad 152.

[0060] Optionally, the depth of the forming groove 101 is 1mm to 2mm, for example, 1.1mm, 1.2mm, 1.3mm, 1.4mm, 1.5mm, 1.6mm, 1.7mm, 1.8mm, or 1.9mm, but is not limited thereto.

[0061] Optionally, such as Figure 6 As shown, the cross-section of the pad 152 is in the positive direction, that is, the pad 152 has four support surfaces 1521. The pad 152 can be rotated 90° to replace the adjacent support surface 1521. The cross-sectional shape of the pad 152 is not limited to this.

[0062] Optionally, Figure 7 This is a schematic diagram of the pad extending along the second direction of this application, as shown. Figure 1 , Figure 6 and Figure 7As shown, the pad 152 is provided with a cooling channel 102. The support device 15 also includes a cooling circulator (not shown). The cooling circulator is connected to the cooling channel 102 and delivers coolant in the cooling channel 102 to reduce the temperature of the pad 152.

[0063] The cooling circulation mechanism of this embodiment can continuously reduce the temperature of the pad 152, ensuring the stability of the dimensions of the pad 152 and the pit on the back of the weld, which not only improves the welding quality but also extends the service life of the pad 152.

[0064] Optionally, the pad 152 is made of copper, which is beneficial for heat conduction and cooling.

[0065] Optionally, the first station is provided with a first positioning element, which is arranged along the first direction X; the automatic plate welding system also includes a first positioning device 22, which is used to push the first plate so that the side edge of the first plate abuts against the first positioning element to achieve side positioning. In this embodiment, the first plate includes a first edge and a second edge, which extend along the first direction X. The first edge and the second edge are arranged opposite to each other along the second direction Y. The first edge is a straight edge parallel to the first direction X, and the second edge is an irregular edge. The first positioning device 22 pushes the first plate so that the first edge contacts the first positioning element, thereby correcting the first plate and ensuring the straightness of the subsequent weld.

[0066] When the conveying device 12 conveys the first plate to the first photoelectric switch 16, it stops conveying. At this time, the controller controls the first positioning device 22 to push the first plate for side positioning. Then, according to the detection of the laser positioning device 18, the controller controls the conveying device 12 to convey the first plate to the third position, completing the pairing of the first plate and the second plate.

[0067] Optionally, the second station is provided with a second positioning element, which is arranged along the first direction X; the automatic plate welding system also includes a second positioning device 23, which is used to push the second plate so that the side edge of the second plate abuts against the second positioning element to achieve side positioning. In this embodiment, the second plate includes a third edge and a fourth edge, which extend along the first direction X and are arranged opposite to each other along the second direction Y. The third edge is a straight edge parallel to the first direction X, and the fourth edge is an irregular edge. The second positioning device 23 pushes the second plate so that the third edge contacts the second positioning element, thereby correcting the second plate and ensuring the straightness of the subsequent weld.

[0068] When the conveying device 12 conveys the second plate to the first position, it stops conveying. At this time, the controller controls the second positioning device 23 to push the second plate for side positioning. Then, according to the detection of the laser positioning device 18, the controller controls the conveying device 12 to convey the second plate to the second position.

[0069] Optionally, the first station is provided with a third positioning element, which is arranged along the first direction X. The third positioning element and the first positioning element are located on opposite sides of the first station. The automatic plate welding system also includes a third positioning device 24, which is used to push the third plate so that the side edge of the third plate abuts against the third positioning element to achieve side positioning. In this embodiment, the third plate includes a fifth edge and a sixth edge, which extend along the first direction X and are arranged opposite to each other along the second direction Y. The fifth edge is an irregular edge, and the sixth edge is a straight edge parallel to the first direction X. The third positioning device 24 pushes the third plate so that the sixth edge contacts the third positioning element, thereby correcting the third plate and ensuring the straightness of the subsequent weld.

[0070] When the conveying device 12 conveys the third plate to the first photoelectric switch 16, it stops conveying. At this time, the controller controls the third positioning device 24 to push the third plate for side positioning. Then, according to the detection of the laser positioning device 18, the controller controls the conveying device 12 to convey the third plate to the third position, completing the pairing of the third plate and the fourth plate.

[0071] It is worth mentioning that the straight edge of the first plate is, for example, close to the left side of the first station, and the straight edge of the third plate is, for example, close to the right side of the first station. Therefore, the plates are side-positioned by setting the first positioning device 22 and the third positioning device 24 respectively.

[0072] Optionally, the second station is provided with a fourth positioning element, which is arranged along the first direction X. The fourth positioning element and the second positioning element are located on opposite sides of the second station. The automatic plate welding system also includes a fourth positioning device 25, which is used to push the fourth plate so that the side edge of the fourth plate abuts against the fourth positioning element to achieve side positioning. In this embodiment, the fourth plate includes a seventh edge and an eighth edge, which extend along the first direction X and are arranged opposite to each other along the second direction Y. The seventh edge is an irregular edge, and the eighth edge is a straight edge parallel to the first direction X. The fourth positioning device 25 pushes the fourth plate so that the eighth edge contacts the fourth positioning element, thereby correcting the fourth plate and ensuring the straightness of the subsequent weld.

[0073] When the conveying device 12 conveys the fourth plate to the first position, it stops conveying. At this time, the controller controls the fourth positioning device 25 to push the fourth plate for side positioning. Then, according to the detection of the laser positioning device 18, the controller controls the conveying device 12 to convey the fourth plate to the second position.

[0074] It is worth mentioning that the straight edge of the second plate is, for example, close to the left side of the second station, and the straight edge of the fourth plate is, for example, close to the right side of the second station. Therefore, the plates are side-positioned by setting the second positioning device 23 and the fourth positioning device 25 respectively.

[0075] Optionally, the first and second plates correspond to the left side plates of the mast, respectively; the third and fourth plates correspond to the right side plates of the mast, respectively.

[0076] Optionally, the first positioning device 22, the second positioning device 23, the third positioning device 24, and the fourth positioning device 25 each include a positioning driver, a drive shaft, and a push plate. One end of the drive shaft is connected to the positioning driver, and the other end is connected to the push plate. The push plate extends from the second shelf 112 to near the first shelf 111 and is positioned directly opposite the first positioning member. The positioning driver drives the drive shaft to move, thereby causing the push plate to push each plate against the positioning member, achieving side positioning. In this embodiment, the positioning driver is, for example, a hydraulic cylinder or a pneumatic cylinder, but is not limited thereto.

[0077] Optionally, the length of the frame 11 can be freely increased or decreased according to actual needs to accommodate the assembly and welding of 3 (3 plates are assembled and welded in sequence), 4 (4 plates are assembled and welded in sequence) or even more plates.

[0078] The automatic plate welding system of this application has the following advantages: First, the welding efficiency is significantly improved compared to traditional manual operation, and the welding cycle time for a single plate is shortened by about 60%.

[0079] Second, the weld formation quality is stable, the single-sided welding double-sided forming effect is reliable, and the defect rate such as porosity and slag inclusion is greatly reduced.

[0080] Third, the positioning accuracy is ≤0.5mm, the assembly gap is uniform, and the welding quality is consistent.

[0081] Fourth, the flatness of the welded sheet metal meets the mast assembly accuracy requirements, and the flatness pass rate of anti-deformation control is ≥95%.

[0082] Fifth, the service life of the pad 152 is extended to more than 4 times that of the traditional solution (4 support surfaces 1521 + multiple repairs), which greatly reduces the cost of consumables.

[0083] This application also relates to an automatic welding method for sheet metal, the automatic welding method for sheet metal utilizing the aforementioned automatic welding system for sheet metal, the automatic welding method for sheet metal comprising: The control conveyor 12 conveys the second plate to the second station and the first plate to the first station; The first lifting part 131 is controlled to drive the first anti-deformation part 132 to rise, so that the first anti-deformation part 132 lifts the first plate and separates it from the conveying device 12, and the first anti-deformation part 132 is controlled to position the first plate on the first positioning surface. The second lifting part 141 is controlled to drive the second anti-deformation part 142 to rise, so that the second anti-deformation part 142 lifts the second plate and separates it from the conveying device 12, and the second anti-deformation part 142 is controlled to position the second plate on the second positioning surface. The control third lifting part 151 drives the pad 152 to fit against the edges of the first plate and the second plate, and makes the first welding edge and the second welding edge corresponding to the forming groove 101; The control welding device welds the first welding edge to the second welding edge together. Please refer to the above for the structure and function of the automatic plate welding system; it will not be repeated here.

[0084] The automatic plate welding method of this application can automatically transport a first plate and a second plate, and use a first anti-deformation device 13 to position the first plate on a first positioning surface and a second anti-deformation device 14 to position the second plate on a second positioning surface. This effectively prevents reverse deformation during welding of the first and second plates, ensuring the flatness of the first and second plates after welding. Furthermore, the automatic plate welding method of this application can automatically position and weld, achieving full automation without manual intervention.

[0085] Optionally, the method for adjusting the distance between the first welding edge and the second welding edge includes: The control conveying device 12 conveys the second plate material sequentially through the first photoelectric switch 16 and the second photoelectric switch 17. Before the second plate passes the first photoelectric switch 16, the control conveying device 12 conveys the second plate at a first speed. When the second plate passes the first photoelectric switch 16, the control conveying device 12 conveys the second plate at a second speed, where the first speed is greater than the second speed. When the second plate passes the second photoelectric switch 17, the control conveying device 12 conveys the second plate at a third speed. The second speed is greater than the third speed. When the laser positioning device 18 detects that the position of the second plate is in the first position, the control conveying device 12 stops conveying the second plate. Based on the deviation between the second plate and the second position, the conveying device 12 is controlled to convey the second plate in the reverse direction to the second position; When the control conveying device 12 conveys the first plate to the first photoelectric switch 16, it stops conveying. Based on the distance between the second welding edge of the second plate and the first welding edge of the first plate detected by the laser positioning device 18, the control conveying device 12 conveys the first plate to the third position so that the first welding edge and the second welding edge are correspondingly set with the forming groove 101.

[0086] In this embodiment, the second plate is conveyed at high speed (first speed) before passing the first photoelectric switch 16, which quickly shortens the conveying time. When the second plate passes the first photoelectric switch 16 but does not reach the second photoelectric switch 17, the conveying device 12 conveys the second plate at medium speed (second speed). After passing the second photoelectric switch 17, the second plate is conveyed at low speed (third speed) to the first position. Then, according to the detection result of the laser positioning device 18, the second plate is conveyed in reverse to the second position, realizing automatic speed reduction of high speed, medium speed and low speed, avoiding overshoot of the plate due to high speed inertia, and also improving welding efficiency.

[0087] Optionally, the automatic welding method for plates in this application further includes: When the second plate reaches the first position, the conveying stops, the second positioning device 23 is controlled to push the second plate for side positioning, and then the conveying device 12 is controlled to convey the second plate to the second position according to the detection of the laser positioning device 18. When the first plate reaches the first photoelectric switch 16, the conveying stops, the first positioning device 22 is controlled to push the first plate for side positioning, and then according to the detection of the laser positioning device 18, the conveying device 12 is controlled to convey the first plate to the third position, completing the pairing of the first plate and the second plate.

[0088] This embodiment adopts a two-stage positioning strategy of coarse positioning + fine positioning. Coarse positioning is achieved by using the first positioning device 22 to perform side positioning on the first plate and the second positioning device 23 to perform side positioning on the second plate, thereby eliminating lateral misalignment. Fine positioning is achieved by using the laser positioning device 18 to provide real-time position feedback and controlling the conveying device 12 to adjust the distance between the first and second plates, thereby eliminating longitudinal end face alignment deviation. This results in uniform assembly gaps, which greatly improves welding quality and ensures weld straightness, resulting in good welding quality consistency.

[0089] Optionally, after the first and second plates are assembled, the following steps are also included: The first lifting part 131 is controlled to drive the first anti-deformation part 132 to rise, so that the first anti-deformation part 132 lifts the first plate and separates it from the conveying device 12. The first magnetic suction device 19 is controlled to generate magnetic force to attract and fix the first plate to the end face of each first telescopic shaft 1322. The first driver 1321 is controlled to drive the first telescopic shaft 1322 to position the first plate on the first positioning surface. The second lifting part 141 is controlled to drive the second anti-deformation part 142 to rise, so that the second anti-deformation part 142 lifts the second plate and separates it from the conveying device 12. The second magnetic suction device 21 is controlled to generate magnetic force to attract and fix the second plate to the end face of each second telescopic shaft 1422. The second driver 1421 is controlled to drive the second telescopic shaft 1422 to position the first plate on the second positioning surface.

[0090] In this embodiment, the first magnetic attraction device 19 and the first anti-deformation part 132 cooperate to pre-apply reverse deformation to the first plate to counteract welding deformation, and the amount of reverse deformation is adjustable (the deformation is adjustable by controlling the magnitude of the magnetic force) to ensure the flatness of the first plate after welding; the second magnetic attraction device 21 and the second anti-deformation part 142 cooperate to pre-apply reverse deformation to the second plate to counteract welding deformation, and the amount of reverse deformation is adjustable (the deformation is adjustable by controlling the magnitude of the magnetic force) to ensure the flatness of the second plate after welding.

[0091] The automatic welding method for plates proposed in this application is applicable to the splicing of long strip plates of different specifications through speed segment control and two positioning strategies. The parameters can be easily adjusted by the controller (PLC), which means it has good versatility.

[0092] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. An automatic welding system for sheet metal, characterized in that, include: The frame includes a first shelf and a second shelf. The first shelf includes a first workstation, an intermediate workstation and a second workstation arranged sequentially along a first direction. The second shelf is disposed above the first shelf and has a first positioning surface facing the first workstation and a second positioning surface facing the second workstation. A conveying device is connected to the first shelf, and the conveying device is used to convey the first board and the second board to the first workstation and the second workstation respectively along the first direction; A first anti-deformation device is provided at the first work station. The first anti-deformation device includes a first lifting part and a first anti-deformation part. The first lifting part is used to drive the first anti-deformation part to rise so that the first anti-deformation part lifts the first plate and disengages it from the conveying device. The first anti-deformation part is used to position the first plate on the first positioning surface. The second anti-deformation device is provided at the second work station. The second anti-deformation device includes a second lifting part and a second anti-deformation part. The second lifting part is used to drive the second anti-deformation part to rise so that the second anti-deformation part lifts the second plate and disengages it from the conveying device. The second anti-deformation part is used to position the second plate on the second positioning surface. A support device is provided at the intermediate work station. The support device includes a third lifting part and a pad block. The pad block is provided with a forming groove. The third lifting part is used to drive the pad block to fit against the edges of the first plate and the second plate. The first welding edge of the first plate and the second welding edge of the second plate are correspondingly provided with the forming groove. A welding device for welding the first welding edge to the second welding edge together.

2. The automatic plate welding system as described in claim 1, characterized in that, The automatic plate welding system further includes a first photoelectric switch, a second photoelectric switch, a laser positioning device, and a controller. The first photoelectric switch, the second photoelectric switch, and the laser positioning device are installed on the second shelf. The first photoelectric switch is positioned at the junction of the first workstation and the intermediate workstation, the second photoelectric switch is positioned at the junction of the second workstation and the intermediate workstation, and the laser positioning device is positioned at the intermediate workstation. The controller is electrically connected to the first photoelectric switch, the second photoelectric switch, the laser positioning device, the conveying device, the first anti-deformation device, the second anti-deformation device, and the support device. The first photoelectric switch and the second photoelectric switch are used to detect the positions of the first plate and the second plate. The laser positioning device is used to detect the distance between the first welding edge and the second welding edge. The controller controls the start / stop and conveying speed of the conveying device based on the signals fed back by the first photoelectric switch and the second photoelectric switch, and controls the conveying device to adjust the distance between the first welding edge and the second welding edge based on the signals fed back by the laser positioning device.

3. The automatic plate welding system as described in claim 1, characterized in that, The first lifting part includes a first lifting drive mechanism and a first platform. The first lifting drive mechanism is connected to the first platform, and the first anti-deformation part is connected to the first platform. The second lifting part includes a second lifting drive mechanism and a second platform. The second lifting drive mechanism is connected to the second platform, and the second anti-deformation part is connected to the second platform.

4. The automatic plate welding system as described in claim 3, characterized in that, The first platform is divided into at least two first placement areas, which are arranged at intervals along the first direction. Each first placement area extends along the second direction, and the second direction has an angle with the first direction. Each first placement area is used to arrange the first anti-deformation part. The first anti-deformation part includes a plurality of first drivers and a first telescopic shaft connected to each of the first drivers. Each of the first drivers is used to drive the first telescopic shaft to position the first plate on the first positioning surface. The second platform is divided into at least two second placement areas, which are arranged at intervals along the first direction. Each second placement area extends along the second direction and is used to arrange the second anti-deformation part. The second anti-deformation part includes a plurality of second drivers and a second telescopic shaft connected to each of the second drivers. Each of the second drivers is used to drive the second telescopic shaft to position the second plate on the second positioning surface.

5. The automatic plate welding system as described in claim 4, characterized in that, The automatic plate welding system further includes a first magnetic suction device, which is disposed on the first platform and is used to generate magnetic attraction to fix the first plate on multiple first telescopic shafts, or the first magnetic suction device is disposed on the second shelf and is used to generate magnetic attraction on the first positioning surface to fix the first plate. The automatic plate welding system further includes a second magnetic suction device, which is disposed on the second platform and is used to generate magnetic attraction to fix the second plate onto multiple second telescopic shafts. Alternatively, the second magnetic suction device can be disposed on the second shelf and is used to generate magnetic attraction on the second positioning surface to fix the second plate.

6. The automatic plate welding system according to any one of claims 1 to 5, characterized in that, The pad includes multiple support surfaces, each of which is used to support the first plate and the second plate, and each of the support surfaces is provided with the forming groove.

7. The automatic plate welding system according to any one of claims 1 to 5, characterized in that, The pad has a cooling channel inside, and the support device also includes a cooling circulator connected to the cooling channel. The cooling circulator delivers coolant in the cooling channel to reduce the temperature of the pad.

8. The automatic plate welding system according to any one of claims 1 to 5, characterized in that, The first workstation is provided with a first positioning component, which is arranged along the first direction; the automatic plate welding system further includes a first positioning device, which is used to push the first plate so that the side of the first plate abuts against the first positioning component. The second workstation is provided with a second positioning component, which is arranged along the first direction; the automatic plate welding system also includes a second positioning device, which is used to push the second plate so that the side of the second plate abuts against the second positioning component; The first workstation is provided with a third positioning component, which is arranged along the first direction and is located on opposite sides of the first workstation, respectively. The automatic plate welding system also includes a third positioning device, which is used to push the third plate so that the side of the third plate abuts against the third positioning component. The second workstation is provided with a fourth positioning component, which is arranged along the first direction and is located on opposite sides of the second workstation, respectively. The automatic plate welding system also includes a fourth positioning device, which is used to push the fourth plate so that the side of the fourth plate abuts against the fourth positioning component.

9. An automatic welding method for sheet metal, characterized in that, The automatic plate welding method utilizes the automatic plate welding system according to any one of claims 2 to 8, and the automatic plate welding method includes: The conveying device is controlled to convey the second sheet material to the second workstation and the first sheet material to the first workstation; Control the first lifting part to drive the first anti-deformation part to rise, so that the first anti-deformation part lifts the first plate and separates it from the conveying device, and control the first anti-deformation part to position the first plate on the first positioning surface. Control the second lifting part to drive the second anti-deformation part to rise, so that the second anti-deformation part lifts the second plate away from the conveying device, and control the second anti-deformation part to position the second plate on the second positioning surface; The third lifting part is controlled to drive the pad block to fit against the edges of the first plate and the second plate, and the first welding edge and the second welding edge are arranged to correspond with the forming groove. The welding device is controlled to weld the first welding edge and the second welding edge together.

10. The automatic welding method for sheet metal as described in claim 9, characterized in that, The method for adjusting the distance between the first welding edge and the second welding edge includes: The control device conveys the second plate material sequentially through the first photoelectric switch and the second photoelectric switch; Before the second plate passes the first photoelectric switch, the conveying device is controlled to convey the second plate at a first speed; When the second plate passes the first photoelectric switch, the conveying device is controlled to convey the second plate at a second speed, wherein the first speed is greater than the second speed; When the second plate passes the second photoelectric switch, the conveying device is controlled to convey the second plate at a third speed, where the second speed is greater than the third speed. When the laser positioning device detects that the position of the second plate is at the first position, the conveying device is controlled to stop conveying the second plate. Based on the deviation between the second plate and the second position, the conveying device is controlled to reverse and convey the second plate to the second position; The conveying device is controlled to stop conveying the first plate when it reaches the first photoelectric switch. Based on the distance between the second welding edge of the second plate and the first welding edge of the first plate detected by the laser positioning device, the conveying device is controlled to convey the first plate to a third position so that the first welding edge and the second welding edge are correspondingly set with the forming groove.

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