Intelligent laser welding device and method based on power distribution cabinet production

Abstract

This invention relates to the field of laser welding technology and discloses an intelligent laser welding device and method for power distribution cabinet production. The device includes: a six-axis articulated robot; a three-axis flipping and positioning fixture for fixing the workpiece and adjusting its posture; and a composite welding head installed at the end of the six-axis articulated robot. The composite welding head includes a laser welding unit, an interlayer pressing and contouring unit, and a wall-mounted air curtain unit. The interlayer pressing and contouring unit is positioned in front of the laser welding unit to press the workpiece before welding and to detect the weld position in real time. The wall-mounted air curtain unit surrounds the laser welding unit and the interlayer pressing and contouring unit. This invention, through spatial coupling and collaborative design of the interlayer pressing and contouring unit and the wall-mounted air curtain unit, constructs a clean, enclosed welding area within a deep cavity, while simultaneously achieving tight bonding of multiple copper busbars and effective capture of spatter, thereby ensuring the quality and stability of multi-layer copper busbar stacking within the deep cavity.

Description

Technical Field

[0001] This invention belongs to the field of laser welding technology, specifically relating to an intelligent laser welding device and method for the production of power distribution cabinets. Background Technology

[0002] In the production and manufacturing of high-voltage switchgear, the cabinet depth is usually over 1200mm. The deepest part of the cabinet has a longitudinal main busbar composed of 2-4 layers of flat copper busbars to form a large cross-section flow channel. The overlapping area needs to be connected by laser welding process. As power grid equipment develops towards large capacity and miniaturization, the internal space of switchgear is becoming increasingly compact. High-quality welding of multi-layer copper busbars in deep cavity has become a key technical challenge that restricts production efficiency and quality.

[0003] Existing laser welding equipment suffers from issues such as spatter rebound and adhesion within the deep cavity, and interlayer gaps in the copper busbars during welding. Some equipment uses a six-axis robot to grip the welding head with a wall-mounted air curtain and insert it deep into the cabinet. A silicone lip cover is used to form a closed welding microcavity to solve the spatter rebound and adhesion problem within the deep cavity. However, the welding head operates directly on the unpressed multi-layer copper busbars. Due to the inconsistent springback after the stamping and bending of each layer of copper busbars, interlayer gaps will occur, resulting in the lower layer not being fused and forming a cold weld. In addition, while an open table environment can effectively ensure the quality of multi-layer copper busbar stacking, a single air curtain anti-spatter technology or a single interlayer pressing technology has a functional disconnect and cannot simultaneously eliminate the two highly coupled technical problems of deep cavity spatter rebound and cold welds caused by interlayer gaps. Summary of the Invention

[0004] This invention provides an intelligent laser welding device for the production of distribution cabinets, which solves the technical problems in related technologies, such as the laser energy attenuation caused by the interlayer gap during the stacking of multi-layer copper busbars in the deep cavity of high-voltage switchgear, resulting in incomplete welding, and the coupling failure of the clamping and conformal rollers due to the rebound and adhesion of spatter in the narrow space of the deep cavity.

[0005] This invention provides an intelligent laser welding device for the production of power distribution cabinets, comprising: Six-axis articulated robot; A three-axis flip-and-position fixture is used to fix the workpiece and adjust its posture. Composite welding head, installed at the end of a six-axis articulated robot; The composite welding head includes a laser welding unit, an interlayer clamping and contouring unit, and a wall-mounted air curtain unit; The interlayer clamping contour unit is located in front of the laser welding unit and is used to clamp the workpiece before welding and detect the weld position in real time. The wall-mounted air curtain unit is arranged around the outside of the laser welding unit and the interlayer pressing and contouring unit to form a closed welding microcavity by fitting with the inner wall of the workpiece. The wall-mounted air curtain unit includes an air curtain generating structure and a negative pressure suction structure. The air curtain generating structure is used to spray protective gas into the welding microcavity to blow away welding spatter, and the negative pressure suction structure is used to extract the gas and spatter from the welding microcavity.

[0006] In a preferred embodiment, the interlayer clamping contouring unit includes a portal frame, a clamping assembly, and a contouring tracking assembly; A portal frame is positioned above the workpiece to be welded; The clamping assembly includes a miniature cylinder and a drum-shaped clamping roller. The miniature cylinder is mounted on a gantry bracket and drives the drum-shaped clamping roller to press down to eliminate the gap between workpiece layers. The contour tracking assembly includes a tracking roller and a differential inductive displacement sensor. The tracking roller rolls along the edge of the workpiece, and the differential inductive displacement sensor is used to detect the displacement difference of the tracking roller and output a weld deviation signal.

[0007] In a preferred embodiment, the wall-mounted air curtain unit further includes a floating connection structure; The floating connection structure includes a guide post and a compression spring. The guide post is connected to the main body of the composite welding head and the air curtain generating structure, respectively. The compression spring is sleeved on the guide post and is used to provide elastic force to make the air curtain generating structure fit against the inner wall of the workpiece.

[0008] In a preferred embodiment, the air curtain generating structure includes a conical air chamber and a lip cover; A conical gas chamber is fitted around the laser welding unit, and the peripheral wall of the conical gas chamber is densely covered with inclined small holes; The lip cover is attached to the end of the conical air chamber and is used to form a seal by contacting the inner wall of the workpiece.

[0009] In a preferred embodiment, the negative pressure suction structure includes a suction port and a negative pressure chip removal pipeline located inside the lip cover, with one end of the negative pressure chip removal pipeline connected to the suction port and the other end connected to the collection tank.

[0010] In a preferred embodiment, the clamping components are symmetrically arranged on both sides of the gantry bracket, and the surface of the drum-shaped clamping rollers is hardened.

[0011] In a preferred embodiment, the lip cover and the conical air chamber are connected by a quick-release structure. The quick-release structure includes a fixing plate, a pressure rod, a pressure ring, a rubber sleeve, and a fixing ring. Two fixing plates are connected to the outer wall of the six-axis robot, two pressure rods are fixedly connected to the side of the fixing plate near the lip cover, the pressure ring is fixedly connected to the end of the pressure rod away from the fixing plate, the rubber sleeve is fixedly connected to the side of the lip cover near the fixing plate, and the fixing ring is connected between the rubber sleeve and the conical air chamber. The fixing ring is fixedly connected to the outer wall of the conical air chamber.

[0012] In a preferred embodiment, the quick-release structure further includes a locking plate and a locking slot disposed on the fixed plate. Rotating the locking plate can separate the locking plate from the locking slot to release the locking of the pressure ring. The bottom surface of the six-axis articulated robot is fixedly connected to a processing base.

[0013] In a preferred embodiment, a control unit is also included, which is signal-connected to the six-axis articulated robot, the three-axis flip-and-shift fixture, the micro cylinder, the differential inductive displacement sensor, and the laser welding unit.

[0014] A smart laser welding method for power distribution cabinet production includes the following steps: Step 1: Adjust the workpiece posture using a three-axis flip-and-position fixture, and move the composite welding head to the welding position using a six-axis articulated robot; Step 2: The wall-mounted air curtain unit adheres to the inner wall of the workpiece to form a closed welding microcavity; Step 3: The interlayer clamping conformal unit clamps the workpiece and detects weld deviations. The control system corrects the welding trajectory based on the deviation signals. Step 4: Start laser welding, and at the same time, the wall-mounted air curtain unit sprays protective gas and starts negative pressure suction; Step 5: The six-axis articulated robot moves the composite welding head along the weld seam to complete the welding.

[0015] The beneficial effects of this invention are as follows: 1. This invention constructs a clean, enclosed welding area in the deep cavity by spatially coupling and coordinating the interlayer pressing conformal unit and the wall-mounted air curtain unit, while simultaneously achieving tight pressing of multiple copper busbars and effective capture of spatter, thereby ensuring the quality and stability of multi-layer copper busbar stacking in the deep cavity. 2. In this invention, the drum-shaped pressing rollers in front of the portal frame reach the welding position before the laser spot under the protection of the air curtain, continuously press each layer of copper busbars under constant pressure, completely eliminate the gap between layers, avoid the existence of air gap energy attenuation medium when the laser penetrates, and ensure that the lower layer is completely fused. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural diagram of an intelligent laser welding device for the production of power distribution cabinets according to the present invention.

[0017] Figure 2 For the present invention Figure 1 Enlarged structural diagram at point A in the middle.

[0018] Figure 3 This is a schematic diagram of the collection tank connection structure of an intelligent laser welding device for the production of power distribution cabinets according to the present invention.

[0019] Figure 4 This is a rear view structural schematic diagram of a composite welding head based on an intelligent laser welding device for the production of power distribution cabinets according to the present invention.

[0020] Figure 5 This is a schematic diagram of the wall-mounted air curtain unit structure of an intelligent laser welding device for power distribution cabinet production according to the present invention.

[0021] Figure 6 This is a schematic diagram of the interlayer pressing contour unit structure of an intelligent laser welding device for power distribution cabinet production according to the present invention. Figure 7 This is a schematic cross-sectional view of the conical air cavity structure of an intelligent laser welding device for the production of power distribution cabinets according to the present invention.

[0022] Figure 8 For the present invention Figure 6 Enlarged structural diagram at point A in the middle.

[0023] Figure 9 This is a schematic diagram of the connecting plate structure of an intelligent laser welding device for the production of power distribution cabinets according to the present invention.

[0024] Figure 10 For the present invention Figure 9 Enlarged structural diagram at point A in the middle.

[0025] Figure Descriptions: 1. Machining base; 2. Flipping and positioning fixture; 3. Six-axis articulated robot; 4. Composite welding head; 5. Negative pressure chip removal pipeline; 6. Collection tank; 7. Control unit; 8. Lip cover; 801. Suction port; 9. Interlayer pressing contour unit; 91. Portal bracket; 92. Miniature cylinder; 93. Drum-shaped pressing roller; 94. Tracking roller; 95. Differential inductive displacement sensor; 10. Wall-mounted air curtain unit; 101. Fixing plate; 1011. Clamping plate; 1012. Clamping slot; 102. Guide post; 103. Compression spring; 104. Pressure rod; 105. Pressure ring; 106. Rubber sleeve; 107. Fixing ring; 108. Conical air chamber; 109. Inclined small hole. Detailed Implementation

[0026] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0027] like Figure 1 , Figure 2 and Figure 3 As shown, an intelligent laser welding device for the production of power distribution cabinets includes: Six-axis articulated robot 3; Three-axis flip-and-position fixture 2 is used to fix the workpiece and adjust its posture; The composite welding head 4 is installed at the end of the six-axis articulated robot 3; The composite welding head 4 includes a laser welding unit, an interlayer pressing and contouring unit 9, and a wall-mounted air curtain unit 10; The interlayer clamping contour unit 9 is located in front of the laser welding unit and is used to clamp the workpiece before welding and detect the weld position in real time. The wall-mounted air curtain unit 10 is arranged around the outside of the laser welding unit and the interlayer pressing and contouring unit 9, and is used to fit against the inner wall of the workpiece to form a closed welding microcavity. The wall-mounted air curtain unit 10 includes an air curtain generating structure and a negative pressure suction structure. The air curtain generating structure is used to spray protective gas into the welding micro-cavity to blow away welding spatter, and the negative pressure suction structure is used to extract the gas and spatter from the welding micro-cavity. It should be noted that although this embodiment uses a six-axis articulated robot 3 as an example, in other alternative embodiments, the multi-degree-of-freedom movement mechanism can also be a Cartesian coordinate robot, a SCARA robot, or a gantry-type linear module, as long as it can drive the composite welding head 4 to the designated welding space position. Similarly, the workpiece posture adjustment mechanism is not limited to the three-axis flip-and-turn positioning fixture 2, but can also be a five-axis linkage positioner or a simple two-axis rotary table depending on the complexity of the workpiece. The purpose is to cooperate with the robot to adjust the workpiece's welding area to the optimal welding posture (such as a boat-shaped welding position). The wall-mounted air curtain unit 10 can cooperate with the negative pressure suction structure to seal the welding area. Then, the negative pressure suction structure performs point-to-point suction of the debris in the welding area, and efficiently treats the side effects generated by the composite welding head 4 during the laser welding process, ensuring the cleanliness of the welding area and not affecting the welding quality.

[0028] refer to Figure 1 and Figure 6 As shown, the interlayer clamping contouring unit 9 includes a portal frame 91, a clamping assembly, and a contouring tracking assembly; A gantry-type support spanning 91 is positioned above the workpiece to be welded; The clamping assembly includes a miniature cylinder 92 and a drum-shaped clamping roller 93. The miniature cylinder 92 is mounted on a gantry bracket 91 and drives the drum-shaped clamping roller 93 to press down to eliminate the gap between workpiece layers. The contour tracking assembly includes a tracking roller 94 and a differential inductive displacement sensor 95. The tracking roller 94 rolls along the edge of the workpiece, and the differential inductive displacement sensor 95 is used to detect the displacement difference of the tracking roller 94 and output a weld deviation signal. It should be noted that the clamping assembly preferably uses a miniature cylinder 92 to drive the drum-shaped clamping roller 93. The driving source of the clamping assembly is not limited to the miniature cylinder 92; it can also use a miniature hydraulic cylinder, an electric push rod, or an electromagnetic actuator. The clamping actuator can also use a ceramic sliding block, an elastic polyurethane pressure plate, or a friction wheel with a knurled texture, as long as it can provide sufficient downward pressure to eliminate the gaps between copper busbar layers. The contour tracking assembly can also use non-contact detection methods, such as a laser line scanning profilometer, a structured light camera, or a fiber optic displacement sensor, to directly scan the three-dimensional coordinates of the copper busbar edge and feed them back to the control unit 7, thereby replacing the mechanical tracking roller 94. The structure of the miniature cylinder 92 and the drum-shaped clamping roller 93 applies pressure to the surface of the copper busbar, reducing the gaps between the multiple copper busbars under pressure. Then, in conjunction with the tracking roller 94, pressure is applied to the edge of the copper busbar to ensure that the copper busbar and the workpiece being processed are in a consistent state during welding.

[0029] refer to Figure 1 , Figure 5 , Figure 7 and Figure 8 As shown, the wall-mounted air curtain unit 10 also includes a floating connection structure; The floating connection structure includes a guide post 102 and a compression spring 103. The guide post 102 is connected to the main body of the composite welding head 4 and the air curtain generating structure, respectively. The compression spring 103 is sleeved on the guide post 102 and is used to provide elastic force to make the air curtain generating structure fit against the inner wall of the workpiece. It should be noted that the floating connection structure can also adopt a pneumatic floating circuit (such as an air-floating connector) to achieve flexible floating by utilizing the compressibility of gas. Alternatively, it can adopt a magnetic levitation guide structure to achieve zero-friction axial floating through magnetic force balance. Or, it can adopt an active compliant control structure based on force sensors to adjust the position in real time through force control feedback from the robot end to simulate the "floating" effect, ensuring that the lip cover 8 always fits the workpiece. The contact part of the lip cover 8 is squeezed by the action of the guide post 102 and the compression spring 103, so that the lip cover 8 at the connection point is pressed tightly against the outer wall of the welding area component under its own hardness and the pressure applied by the compression spring 103, achieving a protective state for the welding area. This ensures that the welding area is in a protected state during the welding process, so that the target of the subsequent structure when suctioning is inside the welding area. This enhances the suction force when extracting debris and ensures the quality of debris processing.

[0030] refer to Figure 1 , Figure 2 , Figure 3 , Figure 7 and Figure 8 As shown, the air curtain generating structure includes a conical air chamber 108 and a lip cover 8; The conical gas cavity 108 is fitted around the laser welding unit, and the peripheral wall of the conical gas cavity 108 is densely covered with inclined small holes 109. The lip cover 8 is connected to the end of the conical air chamber 108 and is used to form a seal by contacting the inner wall of the workpiece; It should be noted that the air curtain generating structure is a conical air chamber 108 with inclined small holes 109, or it can be designed as an annular slit nozzle, that is, laminar gas is ejected through a precision-machined annular slit. Alternatively, a porous sintered metal filter element can be used as the outlet. The protective gas is not limited to argon or nitrogen, but can also be helium or a mixed gas. The lip cover is preferably made of high-temperature resistant silicone material. The lip cover 8 can also be made of fluororubber, polytetrafluoroethylene (PTFE) composite material, or a flexible corrugated tube structure with an internal woven steel wire skeleton. Its cross-sectional shape Not limited to a lip shape, it can also be a labyrinth seal structure or an inflatable seal ring, as long as it can form a relatively closed welding microcavity. By setting a lip cover 8 at the end of the conical air cavity 108, and then spraying gas through the oblique small holes 109 densely distributed on the peripheral wall of the conical air cavity 108, the welding area is flushed with gas. Since the holes of the sprayed gas are in an oblique state, the sprayed airflow will carry the welding debris and flow away from the interlayer pressing contour unit 9, thereby effectively preventing the debris from adhering to the surface of the interlayer pressing contour unit 9.

[0031] refer to Figure 1 and Figure 3As shown, the negative pressure suction structure includes a suction port 801 opened inside the lip cover 8 and a negative pressure chip discharge pipe 5. One end of the negative pressure chip discharge pipe 5 is connected to the suction port 801, and the other end is connected to the collection tank 6. It should be noted that the negative pressure suction preferably has a suction port 801 inside the lip cover 8. Alternatively, a negative pressure generator based on the Venturi principle can be integrated inside the welding head, or an annular suction groove surrounding the laser axis can be used to capture welding fumes at the source. The collection tank 6 draws the debris passing through the suction port 801 into the negative pressure chip discharge pipe 5 for centrifugal treatment. Gas containing metal dust and spatter is efficiently drawn into the collection tank 6 and centrifuged inside. Through centrifugal force, heavier solid particles and debris are effectively separated and collected, while clean air is discharged, thus maintaining the cleanliness of the microcavity and preventing the rollers from seizing. Gas is ejected through the inclined small hole 109 at the end of the conical air chamber 108. The ejected gas blows away debris and other impurities that occur during the welding process, causing the falling debris to separate from the area of ​​the interlayer pressing contour unit 9, preventing... To prevent falling debris from adhering to the structural surface of the interlayer pressing contour unit 9, and to prevent debris from adhering to the surface of the drum-shaped pressing roller 93 or the tracking roller 94 and continuously scraping the copper busbar surface, and to prevent debris from adhering to the drum-shaped pressing roller 93 or the tracking roller 94 and causing contact with the copper busbar, resulting in the copper busbar being dented and deformed, and the welded part being lifted, an inclined small hole 109 is set to blow away the debris. Then, the debris is extracted through the suction port opened in the inner wall of the lip cover 8 by the cooperation of the collection tank 6 and the negative pressure chip removal pipeline 5, so as to uniformly process the falling debris and ensure that the welding area inside the lip cover 8 is in a relatively clean environment during the welding process. The falling speed of the debris is less than the extraction speed of the collection tank 6, thereby ensuring the smoothness of the welding process and the aesthetics of the copper busbar surface after welding.

[0032] refer to Figure 6 As shown, the clamping components are symmetrically arranged on both sides of the gantry bracket 91, and the surface of the drum-shaped clamping roller 93 is hardened. It should be noted that the drum-shaped clamping roller 93 in front of the portal frame 91, under the protection of the air curtain, reaches the welding position before the laser spot, continuously pressing each layer of copper busbars with constant pressure, completely eliminating interlayer gaps, avoiding the presence of air gaps that cause energy attenuation during laser penetration, and ensuring complete fusion of the lower layer. A hardening treatment is applied to the surface of the drum-shaped clamping roller 93, ensuring its surface integrity even under long-term and frequent contact with debris, thus maintaining the tight pressing effect of the drum-shaped clamping roller 93. This ensures that gaps will not appear in the pressing of the copper busbars due to wear on one side, preventing welding problems. Simultaneously, the miniature cylinder 92 provides meticulous pressure treatment to the drum-shaped clamping roller 93, ensuring that the surface of the drum-shaped clamping roller 93 always provides relatively equal pressure to the surface of the copper busbars, ensuring balanced pressure on the copper busbars, and preventing pressure imbalance or problems with pressure on one side that could cause creases. This ensures that the drum-shaped clamping roller 93 can maintain the integrity of the copper busbar surface when applying pressure, thereby ensuring the safety of the structure during use.

[0033] refer to Figure 9 and Figure 10 As shown, the lip cover 8 and the conical air chamber 108 are connected by a quick-release structure. The quick-release structure includes a fixing plate 101, a pressure rod 104, a pressure ring 105, a rubber sleeve 106, and a fixing ring 107. The two fixing plates 101 are connected to the outer wall of the six-axis articulated robot 3. The two pressure rods 104 are fixedly connected to the side of the fixing plate 101 near the lip cover 8. The pressure ring 105 is fixedly connected to the end of the pressure rod 104 away from the fixing plate 101. The rubber sleeve 106 is fixedly connected to the side of the lip cover 8 near the fixing plate 101. The fixing ring 107 is connected between the rubber sleeve 106 and the conical air chamber 108. The fixing ring 107 is fixedly connected to the outer wall of the conical air chamber 108. It should be noted that a groove is provided on one side between the fixing ring 107 and the conical air chamber 108. One side of the rubber sleeve 106 is fixedly connected to the lip cover 8. The side of the rubber sleeve 106 away from the lip cover 8 is located inside the groove. The fixing ring 107 and the rubber sleeve 106 form a snap-fit ​​fixing structure to enhance the sealing performance. Then, the pressure ring 105 compresses the rubber sleeve 106 under the action of the pressure rod 104, so that the contact position between the rubber sleeve 106 and the fixing ring 107 is limited and fixed, and the pressure ring 105 is used to prevent the lip cover 8 from being pushed by external force. This provides a force point for the lip cover 8 to prevent deformation and welding errors. Through the cooperation between the structures, the sealing performance between the structures is improved, and subsequent disassembly and replacement are facilitated, maintaining the long-term high efficiency of the lip cover 8.

[0034] refer to Figure 8 , Figure 9 and Figure 10As shown, the quick-release structure also includes a locking plate 1011 and a locking groove 1012 disposed on the fixed plate 101. Rotating the locking plate 1011 can separate the locking plate 1011 from the locking groove 1012 to release the locking of the pressure ring 105. The bottom surface of the six-axis articulated robot 3 is fixedly connected to the processing base 1. It should be noted that the quick-release structure can also use a magnetic connection (using a strong magnet for adsorption and fixation); or an eccentric wheel cam locking mechanism; or a snap-fit ​​structure; or even a threaded quick-locking ring. Any method that enables quick separation and fixation of the lip cover 8 and the composite welding head 4 is acceptable. The fixing plate 101 is composed of two plates, and the locking plate 1011 is inserted into the locking slot 1012 for positioning. This allows the fixing plate 101 to be fixed to the protruding part at the end of the six-axis articulated robot 3 via an inner protrusion. When post-construction maintenance or replacement of parts of the wall-mounted air curtain unit 10 is required, only manual operation is needed. Rotating the clamping plate 1011 separates it from the slot 1012 on the outer wall of the fixing plate 101 on the other side. Then, the fixing plate 101 can carry the pressure rod 104 and pressure ring 105 on the same side to separate from the rubber sleeve 106. Then, by manually moving the rubber sleeve 106, the protruding part of the rubber sleeve 106 is separated from the fixing ring 107. Then, the rubber sleeve 106 can be separated from the lip cover 8 and the conical air chamber 108. Through the cooperation between the structures, the part of the structure connected to the lip cover 8 can be disassembled at a relatively fast speed, thereby speeding up the maintenance efficiency of the staff and improving the working efficiency of the device.

[0035] refer to Figure 1 , Figure 2 and Figure 6 As shown, it also includes a control unit 7, which is connected to the six-axis articulated robot 3, the three-axis flipping and positioning fixture 2, the micro cylinder 92, the differential inductive displacement sensor 95 and the laser welding unit. It should be noted that the control unit 7 integrates a trajectory correction algorithm, which can process not only analog signals but also digital bus signals. The communication between the control unit 7 and the robot and positioner is not limited to hardwired I / O; fieldbus communication can also be used. In addition, the control unit 7 can also integrate a vision processing module to process the point cloud data collected by the laser profilometer, thereby realizing more complex weld recognition logic (such as breakpoint welding continuation, lap width detection, etc.). By setting the structure of the control unit 7, the electrical signals of the six-axis articulated robot 3, the three-axis flip-and-turn positioner 2, the micro cylinder 92, the differential inductive displacement sensor 95, and the laser welding unit are adjusted to achieve rapid functional response, facilitating the six-axis articulated robot 3 to perform fast and real-time welding tasks.

[0036] A smart laser welding method for power distribution cabinet production includes the following steps: Step 1: Adjust the workpiece posture using the three-axis flipping and positioning fixture 2, and move the composite welding head 4 to the welding position using the six-axis articulated robot 3; Step 2: The wall-mounted air curtain unit 10 adheres to the inner wall of the workpiece to form a closed welding microcavity; Step 3: The interlayer clamping contour unit 9 clamps the workpiece and detects weld deviation. The control system corrects the welding trajectory based on the deviation signal. Step 4: Start laser welding, and at the same time, the wall-mounted air curtain unit 10 sprays protective gas and starts negative pressure suction; Step 5: The six-axis articulated robot 3 drives the composite welding head 4 to move along the weld seam to complete the welding.

[0037] The working principle of this invention is as follows: The high-voltage switch cabinet is fixed on the flip-and-position fixture 2, which is installed on the processing base 1. Driven by a servo motor, it can rotate horizontally, flip vertically, and tilt to the side. The control unit 7 commands the flip-and-position fixture 2 to adjust the multi-layer copper busbar overlap area to be welded in the deep cavity of the cabinet to the best position facing the robot and facilitating welding (e.g., horizontally upward). The six-axis articulated robot 3 holds the composite welding head 4 and goes deep into the cabinet to move to the position to be welded. When the composite welding head 4 reaches the designated position, the outermost lip cover 8 first contacts the inner wall of the cabinet. The lip cover 8 is connected to the internal components through the guide post 102 and the compression spring 103. When it contacts the cabinet wall, the compression spring 103 is compressed, providing a floating stroke of 10-15mm to ensure that the lip cover 8 can fit tightly against the uneven cabinet wall, thereby forming a closed welding area in the deep cavity. After the welding area is formed, the interlayer pressing and contouring unit 9 in the wall-mounted air curtain unit 10 starts to work, and the micro cylinder 92 drives the drum-shaped pressing roller 93. The laser is pressed down and straddled on both sides of the multi-layer copper busbar to eliminate the gaps between the copper busbar layers and prevent the energy attenuation during laser welding from causing incomplete welds. The tracking roller 94 (double V-shaped contour roller) on the top of the portal frame 91 rolls along the edge of the copper busbar. The differential inductive displacement sensor 95 detects the displacement difference of the roller in real time, calculates the lateral deviation of the weld, and feeds the signal back to the control unit 7 to correct the trajectory of the six-axis articulated robot 3 and ensure that the laser focus is always aligned with the center of the weld. The laser inside the composite welding head 4 emits a laser and focuses it on the surface of the workpiece through the protective lens for welding. Compressed air is introduced into the conical air chamber 108, and the airflow is ejected through the circumferentially distributed inclined small holes 109. These small holes form a conical air curtain at a 30-degree angle with the laser optical axis, which blows the spatter generated during welding to the periphery of the lip cover 8 to prevent the spatter from adhering to the lens or roller. At the same time as welding, the negative pressure chip removal pipeline 5 is opened, and the airflow enters the pipeline through the suction port 801 located at the top of the inner side of the lip cover 8. The gas containing metal dust and spatter is sucked into the collection tank 6. In the tank, solid particles are separated and collected, and clean air is discharged, thereby keeping the microcavity clean and preventing the roller from seizing. When the lip cover 8 needs to be replaced after a long period of use, simply rotate the clamping plate 1011 to separate it from the fixing plate 101 on the other side while the shaft is rotating. This separates the clamping plate 1011 from the clamping groove 1012, allowing the two fixing plates 101 to separate. The fixing plates 101 then separate the clamping ring 105 from the rubber sleeve 106 via the pressure rod 104. The rubber sleeve 106 is fixedly connected to the top of the lip cover 8, and the contact surface between the rubber sleeve 106 and the lip cover 8 is a complete annular surface. This enhances the uniformity of the pulling force on the lip cover 8 when the rubber sleeve 106 is connected to the fixing ring 107, ensuring that the lip cover 8 is subjected to uniform force and preventing separation due to external pressure at the break point. Then, the lip cover 8, the negative pressure chip discharge pipe 5, and the collection tank 6 can be disassembled and replaced.

[0038] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. An intelligent laser welding device for the production of power distribution cabinets, characterized in that, include: Six-axis articulated robot (3); A three-axis flip-and-position fixture (2) is used to fix the workpiece and adjust its posture. A composite welding head (4) is installed at the end of the six-axis articulated robot (3); The composite welding head (4) includes a laser welding unit, an interlayer pressing and conforming unit (9), and a wall-mounted air curtain unit (10). The interlayer clamping contour unit (9) is located in front of the laser welding unit and is used to clamp the workpiece before welding and detect the weld position in real time. The wall-mounted air curtain unit (10) is arranged around the outside of the laser welding unit and the interlayer pressing and shaping unit (9) to form a closed welding microcavity by fitting with the inner wall of the workpiece. The wall-mounted air curtain unit (10) includes an air curtain generating structure and a negative pressure suction structure. The air curtain generating structure is used to spray protective gas into the welding microcavity to blow away welding spatter, and the negative pressure suction structure is used to extract the gas and spatter from the welding microcavity.

2. The intelligent laser welding device for power distribution cabinet production according to claim 1, characterized in that, The interlayer pressing contour unit (9) includes a portal frame (91), a pressing assembly, and a contour tracking assembly; The portal frame (91) is positioned above the workpiece to be welded; The clamping assembly includes a miniature cylinder (92) and a drum-shaped clamping roller (93). The miniature cylinder (92) is mounted on the gantry bracket (91) and drives the drum-shaped clamping roller (93) to press down to eliminate the gap between workpiece layers. The contour tracking assembly includes a tracking roller (94) and a differential inductive displacement sensor (95). The tracking roller (94) rolls along the edge of the workpiece, and the differential inductive displacement sensor (95) is used to detect the displacement difference of the tracking roller (94) and output a weld deviation signal.

3. The intelligent laser welding device for power distribution cabinet production according to claim 2, characterized in that, The wall-mounted air curtain unit (10) also includes a floating connection structure; The floating connection structure includes a guide post (102) and a compression spring (103). The guide post (102) is connected to the main body of the composite welding head (4) and the air curtain generating structure, respectively. The compression spring (103) is sleeved on the guide post (102) and is used to provide elastic force to make the air curtain generating structure fit against the inner wall of the workpiece.

4. The intelligent laser welding device for power distribution cabinet production according to claim 3, characterized in that, The air curtain generating structure includes a conical air chamber (108) and a lip cover (8); The conical air chamber (108) is fitted around the laser welding unit, and the peripheral wall of the conical air chamber (108) is densely covered with inclined small holes (109). The lip cover (8) is connected to the end of the conical air cavity (108) and is used to contact the inner wall of the workpiece to form a seal.

5. The intelligent laser welding device for power distribution cabinet production according to claim 4, characterized in that, The negative pressure suction structure includes a suction port (801) and a negative pressure chip removal pipe (5) located inside the lip cover (8). One end of the negative pressure chip removal pipe (5) is connected to the suction port (801), and the other end is connected to the collection tank (6).

6. The intelligent laser welding device for power distribution cabinet production according to claim 5, characterized in that, The clamping components are symmetrically arranged on both sides of the gantry bracket (91), and the surface of the drum-shaped clamping roller (93) is hardened.

7. The intelligent laser welding device for power distribution cabinet production according to claim 6, characterized in that, The lip cover (8) and the conical air chamber (108) are connected by a quick-release structure. The quick-release structure includes a fixing plate (101), a pressure rod (104), a pressure ring (105), a rubber sleeve (106), and a fixing ring (107). The two fixing plates (101) are connected to the outer wall of the six-axis robot (3). The two pressure rods (104) are fixedly connected to the side of the fixing plate (101) near the lip cover (8). The pressure ring (105) is fixedly connected to the end of the pressure rod (104) away from the fixing plate (101). The rubber sleeve (106) is fixedly connected to the side of the lip cover (8) near the fixing plate (101). The fixing ring (107) is connected between the rubber sleeve (106) and the conical air chamber (108). The fixing ring (107) is fixedly connected to the outer wall of the conical air chamber (108).

8. The intelligent laser welding device for power distribution cabinet production according to claim 7, characterized in that, The quick-release structure also includes a card plate (1011) and a card slot (1012) set on the fixed plate (101). By rotating the card plate (1011), the card plate (1011) can be separated from the card slot (1012) to release the lock on the pressure ring (105). The bottom surface of the six-axis articulated robot (3) is fixedly connected to the processing base (1).

9. The intelligent laser welding device for power distribution cabinet production according to claim 8, characterized in that, It also includes a control unit (7), which is connected to the six-axis articulated robot (3), the three-axis flip-and-shift jig (2), the micro cylinder (92), the differential inductive displacement sensor (95), and the laser welding unit.

10. A smart laser welding method for the production of power distribution cabinets, using the welding apparatus according to any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Adjust the workpiece posture using a three-axis flip-and-position fixture (2), and move the composite welding head (4) to the welding position using a six-axis articulated robot (3); Step 2: The wall-mounted air curtain unit (10) is attached to the inner wall of the workpiece to form a closed welding microcavity; Step 3: The interlayer pressing conformal unit (9) presses the workpiece and detects the weld deviation. The control system corrects the welding trajectory according to the deviation signal. Step 4: Start laser welding, and at the same time, the wall-mounted air curtain unit (10) sprays protective gas and starts negative pressure suction; Step 5: The six-axis articulated robot (3) drives the composite welding head (4) to move along the weld seam to complete the welding.

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